The key contents of forging hammer die forging process development include:
① Draw die forging drawing according to forging drawing;
② Define the deformation process plan, mainly the type and sequence of deformation steps;
③ Carry out process design and corresponding groove design;
④ Calculation and selection of raw billet;
⑤ Determine equipment tonnage;
⑥ Define the structural design of forgings, and draw forging drawings;
⑦ Define the heating and cooling standards and heat treatment process of forging blanks;
⑧ Define the trimming process flow and design scheme of trimming die;
⑨ Clarify the process flow and machine equipment for forging cleaning and correction;
⑩ Fill in the die forging process card.
The general process flow of die forging mainly includes blanking, heating, oxide skin removal, blank making, die forging, trimming, heat treatment, surface cleaning, correction, inspection and other processes. The heated steel billet gradually deforms in a series of grooves of the forging, and then becomes a forging. The deformation process of the steel billet in each die chamber of the forging is called die forging step. The die forging process flow is the most important and key component of the die forging process flow. It defines which die forging process step is selected to carry out the forging process flow. The basic process steps of die forging on hammer are divided into the following three types.
1. Blank making working step The key effect of the blank making working step is to redistribute the blank volume or change the axis shape of the blank, effectively distribute the blank volume, so that the cross sectional area of the blank along the axis is consistent with the forging, which is beneficial to filling the cavity with the forging metal. The key work steps of blank making include elevation, length, rolling, pressing, shoulder pressing, clamping, forming, bending, etc.
2. The die making work steps include pre forging and final forging work steps. Its effect is to enable the blank to be forged to obtain forgings of the required shape and size. The cavity used is called the forging die chamber or die forging cavity, and there are two kinds of pre forging and forging. Each forging must be forged, and the pre forging step can be selected according to the actual situation.
3. Cutting work steps The key effect of the cutting work steps is to cut and separate the forgings from the bar stock. When multiple die forgings are selected for one heat, the forged forgings are cut off so that the next forging can be forged again or used to cut the burrs, jaws, etc. The selection of die making steps is based on the shape characteristics of forgings, machine and equipment standards, production and manufacturing standards, production capacity and the operating skills of the staff. The main issues often considered in considering the die forging steps are: whether there are die forging precedents of similar forgings for reference, whether there are fewer work steps to complete the die forging, whether to use pre forgings, how to reduce waste loss, how to facilitate operation, whether to reduce the number of transfers during the blank making process, and whether multiple forgings can be used.