[China Aluminum Network] Die forgings have many closed sections, the distance between the two intercostals is short, the ribs are thin, the spacing between the two ribs and the thickness of the web are large, and many parts of the surface are not processed. Because the forging ribs are much thinner, folding problems often occur at the intersections of thin ribs and webs, ribs, and rims in production. Forgings on the forging collapse its continuity, because it makes the section weakened, or stress concentration occurs in the use of fatigue cracks, to a large extent reduce the forging capacity, and ribs are generally used to give rigidity or for other The parts provide mounting or link faces, so prevent folding defects.

1Aluminum alloy die forging defects and analysis of the reasons for the collapse of the 1.1 die forging folded parts of the forging structure and shape can be seen in the production of folding mostly occurs in the forgings webs and ribs, ribs and edge of the site.

1.2 Causes of Folding Defects 1 Wool design, unreasonable design, resulting in differences in metal distribution. Forging process selection diameter is 180mm × 420mm long bar, according to the second party to play square, until 120mm × 180mm × 480mm, and then pulled out of the middle of its local, and then in the final press molding on the 50 hydraulic press. It can be known from its shape that its upper and lower ribs are symmetrical. Although the appearance of wool is close to the shape of the forgings, the upper part and the bottom part of the forged wool are not uniform, and the bottom metal is distributed in large heights. The height is not enough, and the forgings are symmetrical up and down. During molding, the upper ribs are filled with In the cavity, the lower metal is not filled, and a void is created in the upper corner of the cavity as the deformation occurs. Here, the metal is filled with the lower part to form a fold.

2 Analysis of the fillet radius from webs and ribs. Due to the small radius of the fillets, after the two ribs are filled, the upper and lower dies continue to move closer together. The surface metal passes through the smaller resistance and flows into the burr groove. , And drive the outflow of the surface metal, so that the ribs and the web stack together, resulting in folds.

3 When considering the mold flow from the metal flow direction, the metal-filled cavity does not flow against the rounded wall, leaving the fillet so that the metal comes into contact with the opposite side wall and then comes into contact with the bottom, and metal backflow occurs at the corner. Make the positive flow and the reverse flow metal surface overlap, and then form a fold.

4 The last time the mold was repaired, the repair was not complete, and the fold was not repaired quickly enough to allow it to be pressed into the next molding so that both the inside and the outside of the forging were folded.

1.3 to solve the method of folding defects 1 to change the forging wool into a choice of diameter is 170mm × 280mm long bar, pull long on the pull out of the mold, pull the head is the diameter (170 × 80 +10) mm, the tail is flattened to 70 +5i"~11TI thick. Select new improved wool to mold, you can see the metal from top to bottom is even, and the metal deformation is even in the molding process. The rounded corners will make a smooth transition in the long part of the rod, and make it perpendicular to the parting mold during molding. The flow resistance in the direction is small, and holes cannot be created in the upper corner of the cavity, allowing the metal to fill the cavity evenly.

2 Increase fillets on the ribs and webs and the convex fillet radius on the die so that when the metal is molded, the cavity is filled evenly and the flow resistance is reduced. The excess metal will flow along the burr groove along the contour of the cavity.

3 There is no folding on the surface of the forgings after the improvement process, and the flow lines are distributed along the forgings in accordance with drawings and acceptance standards.

Folding Defects of 2-Axis Forgings In the forgings, the larger part is the shaft-type forgings. The forming mold is a drop mold and consists of two upper and lower parts. During forging, the forging rotates around the axis and there is no flash, for example, a card crash. And straighten the die. The forming of the die is characterized by restricting the lateral flow of the metal through the lateral pressure of the die and extending the metal along the axis. Compared with the free forging, the pull-out rate is increased by ~1120% to 40%. At the same time, the long-term stress inside can also prevent the occurrence of vertical cracks inside. In production, it was found that when the step shaft forgings are forged using a general drop die, folding defects often occur at the step portions.

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