Research on die forging process of aluminum alloy conical cylinder forgings
2022-11-02
The following mainly introduces the die forging process of aluminum alloy conical cylinder forgings, and the characteristics of the defect analysis of the original process.
In the past, aluminium alloy forgings with conical cartridges have been produced using the free forging process, which is upset - drawn - upset - drawn on a hydraulic press and then machined to meet supply conditions. Using the free forging process to produce this forging, a large amount of mechanical processing, serious metal waste, consumption of a large number of manpower. At the same time, productivity cannot be increased due to the large amount of machining required. Therefore, strive to explore a set of both can reduce metal consumption, but also improve the productivity of the production process. The use of die forging technology to produce this product can reduce the amount of metal mechanical processing, save a lot of metal, reduce production time, improve production efficiency, the labor intensity of workers is also greatly reduced.
1. Original production process
The cylinder forgings have always been produced by free forging + mechanical machining. The production process is as follows:
(1) Υ350 mm×900 mm Wool.
(2) Forging: Forge three times on the flat anvil, forging to Υ490+ 10mm× 4200+ 10mm to ensure the diameter of the end.
(3) Forging after heating: drawing long die
(4) Cutting: cut two ends, first cut the small end, cut the shrinkage hole.
2. Analysis of disadvantages of the original process
(1) Low production efficiency
The original process has to go through multiple forging, drawing, sawing and turning processes, and the production cycle from forging to machining into the final product is long.
(2) Low yield
The original process has to go through a lot of cutting and aluminum chips become waste. According to the final product size in Figure 1, the volume of the finished solid part can be calculated as V real =π460×(1012+ 232.52 +101× 232.5)/3-π 340×(722+ 1752+ 72× 175)/3= 25029304.29 mm 3; V real /[π460(1012+ 232.52 + 101 × 232.5)/3]= 59%, the volume of the visible solid part exceeds 1/2 of the total volume.
Calculated yield: finished product quality/wool quality = 25029304× 2.73 /(π350 2× 900/4)× 2.73 ≈29%.
(3) mechanical processing is difficult
The product shape is conical surface, mechanical processing needs to do the process table first, time-consuming and laborious, if outsourced processing, it will have to pay a lot of machining costs (a piece of about 500 yuan), making the production cost high.
Based on the disadvantages of the original process, the mould pressing process is adopted to produce the forging of aluminum alloy cone cylinder.
In the past, aluminium alloy forgings with conical cartridges have been produced using the free forging process, which is upset - drawn - upset - drawn on a hydraulic press and then machined to meet supply conditions. Using the free forging process to produce this forging, a large amount of mechanical processing, serious metal waste, consumption of a large number of manpower. At the same time, productivity cannot be increased due to the large amount of machining required. Therefore, strive to explore a set of both can reduce metal consumption, but also improve the productivity of the production process. The use of die forging technology to produce this product can reduce the amount of metal mechanical processing, save a lot of metal, reduce production time, improve production efficiency, the labor intensity of workers is also greatly reduced.
1. Original production process
The cylinder forgings have always been produced by free forging + mechanical machining. The production process is as follows:
(1) Υ350 mm×900 mm Wool.
(2) Forging: Forge three times on the flat anvil, forging to Υ490+ 10mm× 4200+ 10mm to ensure the diameter of the end.
(3) Forging after heating: drawing long die
(4) Cutting: cut two ends, first cut the small end, cut the shrinkage hole.
2. Analysis of disadvantages of the original process
(1) Low production efficiency
The original process has to go through multiple forging, drawing, sawing and turning processes, and the production cycle from forging to machining into the final product is long.
(2) Low yield
The original process has to go through a lot of cutting and aluminum chips become waste. According to the final product size in Figure 1, the volume of the finished solid part can be calculated as V real =π460×(1012+ 232.52 +101× 232.5)/3-π 340×(722+ 1752+ 72× 175)/3= 25029304.29 mm 3; V real /[π460(1012+ 232.52 + 101 × 232.5)/3]= 59%, the volume of the visible solid part exceeds 1/2 of the total volume.
Calculated yield: finished product quality/wool quality = 25029304× 2.73 /(π350 2× 900/4)× 2.73 ≈29%.
(3) mechanical processing is difficult
The product shape is conical surface, mechanical processing needs to do the process table first, time-consuming and laborious, if outsourced processing, it will have to pay a lot of machining costs (a piece of about 500 yuan), making the production cost high.
Based on the disadvantages of the original process, the mould pressing process is adopted to produce the forging of aluminum alloy cone cylinder.
To sum up, it can be seen that using die forging process to produce aluminum alloy conical cylinder forgings, not only the yield is greatly increased, but also the product has good mechanical properties, the production cycle is shortened a lot, and the economic benefits are greatly improved. Therefore, the die forging process determined in this paper is feasible.
this is open die forgings produced by tongxin precision forging company
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