METHOD OF RADIAL FORGING OF BLANK

Abstract: A method of radial forging of a blank where the blank (1) is placed in the manipulator head (2), swaged by at least two pairs of oppositely mounted pressing block-heads (3, 4 and 5, 6), while applying at the same time the normal swaging force of the said pairs of the pressing block-heads and a shearing force T, then is moved along the longitudinal axis 00 or turned about the longitudinal axis 00 and is moved along the same longitudinal axis 00, the operation of swaging the blank (1) being carried out simultaneously at its two sections A and B situated consecutively along its longitudinal axis 00, the shearing force T being applied at these sections in opposite directions.

Description: Field of technology The invention pertains to the area of mechanical metal-working and deals, in particular, with the method of manufacturing long forgings from ingots and continuous cast billets. Applying the method of the present invention, a blank is mounted into a clamping head of at least one manipulator and swaged at least by two pairs of oppositely arranged faces, there being applied in the process forces of normal linear reduction which are created by said pairs of faces, and, at the same time, a shearing force. Thereafter the blank is displaced along the longitudinal axis, before the indicated displacement, is rotated along the longitudinal axis, after which the entire process of processing the blank is repeated until the given geometrical dimensions of the forging are obtained. This method can be used in machine building and metallurgy for manufacturing long products like rods, columns, shafts and so on; manufacturing pre-forged intermediate products from special, stainless, heat-resistant and hard-wrought alloys to be later worked mechanically into rods; pre-forging of job workpieces from the above mentioned alloys for subsequent mechanical dividing into uniform parts and also for forging conventionally cast ingots and continuous cast billets into deformed ones. Preceding level of technology There's known a method of radial forging of ingots and continuous cast billets with the help of radial forging machine (see, for instance, an advertisement leaflet of "SMS" company "Radial forging machine. Advanced extension and forging technology". P'/327. SMS Hasenklever, 3000/4/90 Sch.). By this method the initial blank is heated first, then it is set up into the chuck head of manipulator and after that fed into the interspace of the forming tools, being simultaneously rotated for producing forgings of round cross-sections while without rotation forgings of square or rectangular cross-sections are obtained. The blank is swayed at the same part along its length in the working zone, in turn by each pair of forging tools moving radially in one plane to the blank's axis. During the intervals between swagings, when the forging tools accomplish their back travel, the blank is moved in the axial direction, when forgings of square and rectangular cross-sections should be obtained, or the blank is rotated around its longitudinal axis and moved lengthwise when forgings of round cross-sections should be obtained. The mentioned above operational cycle is repeated over and over reducing the blank to the required sizes. The considered forging method makes it possible to obtain the deformation of cast metal structure mainly in the axial zone of the forging. However, when using the mentioned above known method of radial forging, there occasionally takes place the opening of cavities of shrink origin in ingots or continuous cast billets in their axial zones at the stage of swaging. Besides, the area reduction is 5:1 what leads to the necessity to have the initial billet with cross-section area five times larger than the cross-section area of the forging. In accordance with another method of forging ingots and continuous cast billets with the help of a radial-swaging machine (see, for instance, an advertisement leaflet of "Danieli" company "New forging installations with Danieli hydraulic forging machines", October 15, 1987, AD/f6) the initial conventionally cast ingot or continuously cast billet is heated first, then it is set up into the chuck head of manipulator and after that fed into the interspace of the forging tools, being simultaneously rotated for producing forgings of round cross-sections while without rotation for producing forgings of square or rectangular cross-section are obtained. The working interspace is formed by four forging tools. The forging tools move radially in one plane toward each other to billet's axis. Besides, the forging tools move in the same tangential direction. The mentioned forging tools swage the blank simultaneously at one portion of its length. During the intervals between swagings, when the forging tools accomplish their back travel, the blank is being rotated around its longitudinal axis and moved lengthwise, when forgings of round cross-sections should be obtained, or just moved lengthwise, when forgings of square and rectangular cross-sections should be obtained. The mentioned above operational cycle is repeated over and over swaging the blank lengthwise to the required sizes. The considered forging method makes it possible to obtain a forging with dense metal macrostructure in its axial zone and the deformation of cast metal structure mainly in its surface zone. However, when using the mentioned above known method of forging the forging ratio is 3:1 what leads to the necessity to have the initial blank with cross-section area three times larger than the cross-section area of the forging. In SU-A-393 018 a process of linearly reducing a blank on two successive sections to be performed by applying shearing forces in opposite directions is disclosed. Shearing forces are applied only on the section between two parts of one zone of deformation and only in one transverse plane. US-A-4 300 378 discloses a method for easing the deformation of a blank by reducing the axial longitudinal stress. One rotating die part is used to create shearing forces. Thus, none of the existing known radial forging methods give an opportunity to obtain a forging will, dense metal macrostructure both in its surface and axial zones with the forging ratio less than 3:1. Description of invention The goal of this invention is to create a new method of radial forging of blank that would make it possible to obtain forged products with dense metal macrostructure in their axial zones and at the same time with uniformly deformed metal structure both in their surface and axial zones with forging ratio less than 3:1. This goal is achieved through the fact that shearing forces are created simultaneously at least on two successive sections (A) and (B) by means of linear reduction of the blank by two pairs of faces performing displacement in opposite directions correspondingly over arcs of circles with centres on the longitudinal axis of the blank. During the performance of the two pairs of faces a shearing force is additionally created by rotating the blank around its longitudinal axis by means of the clamping head (2) at least of one manipulator. Said shearing force is commensurate with the force (P) of normal linear reduction by the faces and coinciding with the direction of the shearing force on the adjacent section. This gives an opportunity to make the metal structure denser in the axial zone of the forging. This provides uniform deformation of cast metal structure both in the surface and axial zones of the forging. This technique permits to obtain blank's deformation through the bigger part of its length beyond the portion being directly in the swaging zone. It is appropriate to adjust the shearing force, created by the chuck head of manipulator, approximately comparable in magnitude with the normal swaging force, created by every pair of the forging tools. This gives an opportunity to secure blank's deformation at the portion that is out of the swaging zone, comparable with blank's deformation at the portion that is in the swaging zone. It is expedient to make this turn with the change of rotation direction of the chuck head. This technique permits to obtain the twisting of forging's metal fibres arranged in the same direction or in different ones in forging's length including the case of fibres' orientation parallel to the forging's axis. It is possible to swage the blank first with one pair of forging tools applying the shearing forces in one direction and then with the other pair applying the shearing forces in the opposite one. It gives an opportunity to improve the deformation of the cast metal structure in the axial zone of the forging. Below is given a particular example describing, in accordance with the invention, the realization of the offered new method of radial forging of blank with an accompanying schematic axonometric draft showing a general view of cylindrical blank placed in the chuck heads of manipulators and swaged by two pairs of oppositely mounted forging tools. The best version of invention's realization The method of radial forging of blank being patented is implemented in the following way. The initial blank (1) (see the draft), for instance, ingot or continuous cast billet of, let us say, round cross-section is placed in chuck head (2) of manipulator and then fed into the working space between two sets of forging tools (3,4 and 5,6) with every set consisting of two pairs of oppositely mounted forging tools. The blank (1) is swaged by first pair (3) and second pair (4) of forging tools at portion A while applying normal swaging force P, created by the said pairs (3 and 4), and at the same time shearing force T. The blank is simultaneously swaged by third pair (5) and fourth pair (6) of forging took at position B, lying farther along blanks axis 00, applying shearing force T' in the opposite direction. But the number of such forging tools pairs may be more. For better understanding only four pairs of forging tools are shown on the draft. In the process of swaging of blank (1) at portions A and B there appear normal compression stresses and strains in the axial zone and likewise shearing deformation in the surface zone. At the same time as the result of applying the oppositely directed shearing forces T and T' at adjacent portion A and B of blank (1) there take place large shearing strains between these two portions spreading all over the cross-section of blank (1). When forging tools (3,4 and 5,6) accomplish their back travel in the direction of arrow F and F' blank (1) is moved along longitudinal axis 00 in the direction of arrow K. When forging tools (3,4 and 5,6) accomplish their back travel in the direction of arrows F and F' blank (1) can be turned around its longitudinal axis 00 in the direction of arrow G and moved along the same longitudinal axis 00 in the direction of arrow K, whereupon the swaging of blank (1) should be kept on in the manner described above up to getting the required geometric sizes of the forging. The shearing forces can be created by swaging blank (1) with pairs of forging tools (3,5 and 4,6) each moving in its own arc C and C' with the circumference center on the longitudinal axis 00 of blank (1) while one pair of forging tools (3 or 4) is moving in arc of the circumference in one direction and the other pair (5 or 6) in arc C' of the circumference in the opposite one. Such method of creating shearing forces gives an opportunity to provide additional macroshearing strains in blank (1) being swaged between portions A and B. The macroshearing strains make a considerable effect on deformation of cast metal structure with low forging ratios of approximately less than 2:1. It is possible to create shearing force T by turning at least one blank's (1) portion, that is out of swaging zone A of forging tools (3 and 4), around blank's longitudinal axis 00 with the help of chuck head (2) of manipulator. When the mentioned above portion of blank (1) is being turned there appear torsion strains in that portion acting effectively on the cast metal structure and causing the twisting of the fibres of metal macrostructure. If it is necessary to twist blank's (1) portion, that is between parts A and B, the mentioned operation can be done with the help of chuck head (2) at the moment when pairs of forging tools (3,4) accomplish their back travel in the direction of arrow F, or with the help of chuck head (7) at some other moment when the other pairs of forging tools (5,6) accomplish their back travel in the direction of arrow F'. It is advisable to adjust shearing force T, created by chuck head (2) of manipulator, approximately comparable in magnitude with normal swaging force P, created by forging tools (3 and 4). In this case, there appear torsion strains in blank (1) approximately comparable with strains arising from the normal swaging with mentioned above pairs of forging tools (3,4 and 5,6). The torsion strains take place with almost unchanged area of blank's cross-section what makes possible deformation of cast metal structure with low forging ratio, approximately less than 2:1. If is possible the said turning of blank (1), done by chuck head (2) of manipulator, to perform, with the change of rotation direction of chuck head (2) following arrow G'. The indicated change of rotation direction of chuck head (2 or 7) makes it possible to create torsion strain of blank (1) in the opposite direction and, thus, to change the twisting direction of fibres of metal macrostructure to the opposite one, that is following arrow G'. Such technique permits to regulate the arrangement of fibres in length of blank (1) and obtain the final direction of metal fibres in a product consistent with the action of internal stresses during product's operation. As it is known, the said internal stresses can act in different directions in length of a forged product. According to the method being patented it is possible first to swage blank (1) with the help of one pair of forging tools (3 or 4) applying shearing force T in one direction and then with the help of one pair of forging tools (5 or 6) applying shearing force T' in the opposite direction. This technique of applying shearing forces T and T' in opposite directions gives an opportunity to obtain cumulative macroshearing strains in different directions and, thus, to act effectively on the deformation of cast metal structure almost without change of cross-section area obtained after blank's swaging, that is with minimum forging ratio less than 2:1. If there are two manipulators, it is possible to mount the blank in chuck head (7) of the second manipulator and carry out all mentioned above operations with blank (1) what enables an increase in production output. At the same time the realization of all above described operations on blank (1) with the help of chuck head (7) of the second manipulator extends control over the fibres' arrangement pattern in metal structure of the forging and over the anisotropy of its mechanical properties. An example A cylindrical pure aluminum ingot of 76 mm in diameter was set up in the chuck head of manipulator of radial swaging machine and swaged with two pairs of forging tools simultaneously at two ingot's portions, each of 40 mm long, located one after another along ingot's longitudinal axis. The shearing force of every pair of oppositely mounted forging tools was applied to the ingot at each portion in opposite directions. In intervals between swagings the ingot was rotated around its longitudinal axis and moved along this axis. The whole operational cycle was repeated to reduce ingot's diameter to 56 mm. Thus, the forging ratio came approximately to 2:1. The analysis of metal's macrostructure revealed uniform and dense structure all over the cross-section area of forging with fibres twisted approximately through 360°. Industrial applicability Thus, the claimed method of radial forging of blank gives an opportunity to obtain uniform and dense metal structure all over the cross-section area with insignificant forging ratio of approximately 2:1. The application of the claimed method of radial forging of blank enables an essential increase in swaging production output, considerable reduction in power consumption and using initial blanks of smaller cross-sections. It is quite obvious that using initial blanks of smaller cross-sections according to the claimed method of radial forging of blank costs considerable, less than in case of using large blanks. Apart from the increase in swaging production output the claimed method makes it possible to obtain high quality deformation of metal structure. As a result, a substantial improvement of mechanical properties of metal is obtained what is not possible with the use of other known methods of radial forging of blank with low forging ratio of approximately 2:1.

Claims: Method for the radial forging of a blank, consisting in that the blank (1) is mounted in a clamping head (2) of at least one manipulator and swaged at least by two pairs of oppositely arranged faces (3, 4), there being applied in the process forces (P) of normal linear reduction which are created by the said pairs of faces, and, at the same time, a shearing force (T); thereafter the blank (1) is displaced along the longitudinal axis or, before the indicated displacement, is rotated around the longitudinal axis, after which the entire process of processing the blank (1) is repeated until the given geometrical dimensions of the forging are obtained, characterized in that the shearing forces are created simultaneously at least on two successive sections (A) and (B) by means of linear reduction of the blank (1) by two pairs of faces (3, 4; 5, 6) performing displacement in opposite directions correspondingly over arcs of circles (C, C') with centres on the longitudinal axis of the blank (1) and during the performance of the two pairs of faces a shearing force is additionally created by rotating the blank (1) around its longitudinal axis by means of the clamping head (2) at least of one manipulator, the said shearing force being commensurate with the force (P) of normal linear reduction by the faces and coinciding with the direction of the shearing force (T) on the adjacent section. Method according to Claim 1, characterized in that the linear reduction of the blank (1) on each section (A, B) is performed by one of the pairs of faces (3, 4; 5, 6), forces being applied on opposite directions and the pairs of faces being selected in an unlike fashion, and then by the other pairs of faces accompanied by a change in the direction of application of the forces, there being a simultaneous change in the direction of rotation of the clamping head (2) of the manipulator.

Inventors: KUROLES VITALY IVANOVICH, LAZORKIN VIKTOR ANDREEVICH, TJURIN VALERY ALEXANDROVICH, VOLODIN ALEXEI MIKHAILOVICH, KUROLES, VITALY IVANOVICH, LAZORKIN, VIKTOR ANDREEVICH, TJURIN, VALERY ALEXANDROVICH, VOLODIN, ALEXEI MIKHAILOVICH
Applicants: TJURIN VALERY ALEXANDROVICH, TJURIN, VALERY ALEXANDROVICH
Application year: 1993
Main classification: B21J1
IPC codes: B21J5, B21J7, B21J1