多向模锻制造技术及其装备研制

Multi-ram Forge Process and Its Equipment Development

多向模锻又称为多柱塞模锻,可以在一次加热和压机一次行程中完成复杂形状、特别是带内腔或凹凸外形锻件的锻造。其锻件的性能好,并可提高材料利用率1倍以上,减少后续切削加工量。因此,多向模锻是一种精密优质、节能省材的绿色锻造技术。但大、中型多向模锻需要的重型多向模锻液压机,要能够在水平和垂直两个方向提供压制力。与普通液压机比较,多向模锻液压机在承载机架的设计与制造上存在较大的难度。针对此关键技术问题,提出基于预应力钢丝缠绕的'正交预紧机架'结构。利用预应力钢丝缠绕,对整体机架同时产生垂直和水平两个方向的预紧力,以平衡多向压制载荷。应用正交预紧机架设计制造的40 MN/64 MN多向模锻液压机,验证该新型结构的有效性和可行性。这一技术突破为在我国推广多向模锻制造技术,促进我国锻造行业的节能、减排和技术进步,奠定了技术保障。

The multi-ram forge can form the parts with complex shape,especially with hollow or concavo-convex feature,within single heating and single stroke.The properties of forged parts are higher than those by conventional close die forge process.The multi-ram forge process will also save the material and machining time.So,it could be regarded as a green forge technique with high accuracy and quality,saving energy and material.But the development of heavy multi-ram forge hydraulic presses,which will provide the huge vertical and horizontal forging or piercing forces to producing large or middle size parts,is a big engineering challenge compared to the conventional forge press.Based on the prestressed wire-wound technique,a novel orthogonal preload frame is proposed,which could provide vertical and horizontal preloads simultaneously to prevent the multi-way forging or piercing forces with the prestressed wire wounding along the special designed frame contour.The new frame structure has been investigated in the development of a 40 MN/64 MN multi-ram forge hydraulic press,whose frame is designed as an orthogonal preload frame.This breakthrough provides the fundamental technology for implementing the multi-ram forge process in China,and will promote the technical progresses to save energy and reduce emission for Chinese forge industry.