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半弧板鍛件成(cheng)形工藝研究

文章來源：sjzwx 更新(xin)時(shi)間：2015-05-25 09:18:30

    兩(liang)端半弧板成(cheng)(cheng)形(xing)(xing)(xing)工(gong)藝(yi)(yi)研究半弧板鍛(duan)(duan)件(jian)形(xing)(xing)(xing)狀(zhuang)較(jiao)復雜，按照傳統工(gong)藝(yi)(yi)方(fang)法(fa)損(sun)料多，材(cai)料實際利用(yong)率(lv)相對較(jiao)低，必然增(zeng)加車間生產成(cheng)(cheng)本。通過認(ren)真(zhen)分析鍛(duan)(duan)件(jian)形(xing)(xing)(xing)狀(zhuang)，確定采(cai)取兩(liang)件(jian)錯位(wei)合(he)鍛(duan)(duan)一氣割(ge)成(cheng)(cheng)形(xing)(xing)(xing)的(de)方(fang)法(fa)組(zu)織生產。半弧板鍛(duan)(duan)件(jian)成(cheng)(cheng)形(xing)(xing)(xing)示意(yi)圖見圖2。通過采(cai)用(yong)兩(liang)件(jian)合(he)鍛(duan)(duan)的(de)成(cheng)(cheng)形(xing)(xing)(xing)工(gong)藝(yi)(yi)，不僅降(jiang)低了鍛(duan)(duan)件(jian)工(gong)藝(yi)(yi)重量和工(gong)藝(yi)(yi)損(sun)耗，而且克服(fu)了因鍛(duan)(duan)件(jian)形(xing)(xing)(xing)狀(zhuang)復雜導(dao)致(zhi)車間組(zu)織生產難度較(jiao)大的(de)問題(ti)。

    中間(jian)長弧板成(cheng)形(xing)工(gong)藝(yi)研究(jiu)長弧板鍛(duan)(duan)(duan)(duan)件形(xing)狀較特(te)別，若按照傳統工(gong)藝(yi)方法直接鍛(duan)(duan)(duan)(duan)成(cheng)方板，則增加了(le)(le)鍛(duan)(duan)(duan)(duan)件工(gong)藝(yi)重(zhong)量。通過(guo)(guo)認真(zhen)分析鍛(duan)(duan)(duan)(duan)造(zao)變(bian)形(xing)工(gong)藝(yi)，基于(yu)金屬塑性流動(dong)原理(li)，利用鍛(duan)(duan)(duan)(duan)造(zao)過(guo)(guo)程(cheng)中產生(sheng)舌頭鼓出兩端弧形(xing)，如圖3所示。通過(guo)(guo)充分利用鍛(duan)(duan)(duan)(duan)造(zao)過(guo)(guo)程(cheng)中產生(sheng)的(de)舌頭，不僅容易保證鍛(duan)(duan)(duan)(duan)件兩端的(de)弧度尺寸，而且生(sheng)產操作控制(zhi)(zhi)簡單，也降低了(le)(le)鍛(duan)(duan)(duan)(duan)件制(zhi)(zhi)造(zao)成(cheng)本。

    主(zhu)變(bian)形(xing)(xing)方(fang)案分析由于本批次管板技(ji)術要求(qiu)嚴(yan)格，而(er)且(qie)截面大、高(gao)度(du)低(di)，心部(bu)(bu)(bu)極易產生片狀夾(jia)雜(za)缺(que)陷，基于此(ci)主(zhu)變(bian)形(xing)(xing)鐓拔(ba)(ba)(ba)(ba)階(jie)段(duan)采(cai)取(qu)寬(kuan)砧強壓拔(ba)(ba)(ba)(ba)方(fang)法，大進(jin)砧量(liang)、大壓下量(liang)進(jin)行鍛(duan)造，充分打碎(sui)粗大組織，焊合(he)孔洞(dong)性缺(que)陷。W／H(一(yi)(yi)砧子(zi)寬(kuan)度(du)，日一(yi)(yi)坯料壓前高(gao)度(du))控制在0．5～0．8，保證坯料心部(bu)(bu)(bu)的應(ying)力(li)、應(ying)變(bian)狀態。壓下率AH／H控制在16％～22％，保證閉合(he)面積(ji)最大。主(zhu)變(bian)形(xing)(xing)拔(ba)(ba)(ba)(ba)扁(bian)初始階(jie)段(duan)采(cai)取(qu)寬(kuan)砧強壓拔(ba)(ba)(ba)(ba)扁(bian)、坯料局(ju)部(bu)(bu)(bu)成形(xing)(xing)，金(jin)屬(shu)(shu)基體以局(ju)部(bu)(bu)(bu)整體流(liu)動為主(zhu)，使得(de)受壓部(bu)(bu)(bu)位心部(bu)(bu)(bu)承(cheng)受一(yi)(yi)定的靜水(shui)壓力(li)，減弱(ruo)了(le)夾(jia)雜(za)物成為片狀的趨(qu)勢j。拔(ba)(ba)(ba)(ba)完一(yi)(yi)趟后(hou)翻轉180。進(jin)行第二趟拔(ba)(ba)(ba)(ba)扁(bian)，壓下率AH／H控制在14％～17％之間，合(he)理控制送(song)進(jin)量(liang)。主(zhu)變(bian)形(xing)(xing)拔(ba)(ba)(ba)(ba)扁(bian)接近(jin)出成品階(jie)段(duan)采(cai)用窄砧拔(ba)(ba)(ba)(ba)扁(bian)拔(ba)(ba)(ba)(ba)長(chang)。變(bian)形(xing)(xing)進(jin)行到(dao)(dao)此(ci)階(jie)段(duan)，內部(bu)(bu)(bu)組織基本上(shang)(shang)得(de)到(dao)(dao)了(le)充分壓實，成形(xing)(xing)力(li)較(jiao)大，金(jin)屬(shu)(shu)流(liu)動較(jiao)為困難。采(cai)用窄砧拔(ba)(ba)(ba)(ba)扁(bian)拔(ba)(ba)(ba)(ba)長(chang)降低(di)了(le)成形(xing)(xing)力(li)，再則砧子(zi)與坯料的接觸面積(ji)減小，一(yi)(yi)定程度(du)上(shang)(shang)改善了(le)金(jin)屬(shu)(shu)塑性流(liu)動狀況，利(li)于鍛(duan)件成形(xing)(xing)。

    工(gong)(gong)藝(yi)(yi)方(fang)(fang)案主要亮點(dian)和(he)過(guo)程(cheng)控制(zhi)(zhi)(zhi)關鍵點(dian)(1)該(gai)工(gong)(gong)藝(yi)(yi)方(fang)(fang)案主要亮點(dian)：很大程(cheng)度上實(shi)現(xian)了(le)(le)按照(zhao)管板零件(jian)(jian)(jian)輪廓形(xing)(xing)(xing)狀進(jin)(jin)行(xing)成(cheng)形(xing)(xing)(xing)，且生(sheng)(sheng)產(chan)操(cao)作較(jiao)為方(fang)(fang)便，尺寸(cun)(cun)也(ye)較(jiao)容易控制(zhi)(zhi)(zhi)。兩端半弧(hu)(hu)板鍛(duan)件(jian)(jian)(jian)錯位合(he)鍛(duan)一氣割的工(gong)(gong)藝(yi)(yi)方(fang)(fang)法一定程(cheng)度上解決了(le)(le)形(xing)(xing)(xing)狀較(jiao)為復雜大型鍛(duan)件(jian)(jian)(jian)的成(cheng)形(xing)(xing)(xing)問題，且通過(guo)合(he)理(li)利(li)用(yong)兩端余(yu)料鍛(duan)制(zhi)(zhi)(zhi)本(ben)體(ti)試(shi)板，更好的貼合(he)了(le)(le)鍛(duan)件(jian)(jian)(jian)本(ben)身綜合(he)性能。長弧(hu)(hu)板的鍛(duan)造充分利(li)用(yong)了(le)(le)金屬(shu)流動(dong)規律，解決了(le)(le)端部弧(hu)(hu)形(xing)(xing)(xing)輪廓的成(cheng)形(xing)(xing)(xing)，達到了(le)(le)降低(di)生(sheng)(sheng)產(chan)成(cheng)本(ben)的目的。(2)該(gai)工(gong)(gong)藝(yi)(yi)方(fang)(fang)案生(sheng)(sheng)產(chan)過(guo)程(cheng)控制(zhi)(zhi)(zhi)關鍵點(dian)：鐓拔階段嚴格按照(zhao)工(gong)(gong)藝(yi)(yi)參數進(jin)(jin)行(xing)生(sheng)(sheng)產(chan)操(cao)作，合(he)理(li)控制(zhi)(zhi)(zhi)進(jin)(jin)砧量(liang)和(he)壓下量(liang)。拔扁過(guo)程(cheng)中應根據具體(ti)生(sheng)(sheng)產(chan)情(qing)況(kuang)(kuang)及時調整操(cao)作方(fang)(fang)法，保(bao)證鍛(duan)件(jian)(jian)(jian)成(cheng)形(xing)(xing)(xing)質量(liang)。另外，由于鍛(duan)件(jian)(jian)(jian)形(xing)(xing)(xing)狀的特殊性，接近工(gong)(gong)藝(yi)(yi)尺寸(cun)(cun)后，要及時用(yong)事先做好的樣板比對，特別要關注長弧(hu)(hu)板兩端弧(hu)(hu)度的成(cheng)形(xing)(xing)(xing)情(qing)況(kuang)(kuang)，防止(zhi)尺寸(cun)(cun)超差。