薄煤层液压支架用大型柱窝模锻成形工艺及模具设计

Die forging process of large-scale pillar nest used in hydraulic support for thin coal seam and its die design

针对薄煤层液压支架上大型、薄壁、高落差、高减重孔类柱窝锻件在锻造成形中易产生错移、球窝面及窝口变形、拔模后截距大、截面积突变明显、成形载荷大、模具寿命低的问题,提出一种新的锻造成形方式。通过采用曲面分模、模具型腔倾斜放置、渐变拔模、减少模具闭合高度等方法,实现了此类型柱窝的锻造成形及顺利出模。结果表明,通过对模具结构、模具材料、热处理硬度的合理设计,可以达到提高锻件质量、减小机械加工余量、减少打击次数、缩短打击时间、提高生产效率、降低生产成本的目的。通过长时间对大型模锻件成形工艺的研究,总结出锻造行业国家标准中没有的大型锻件的工艺参数。

For the problems that the pillar nest forgings with large scale,thin wall,high drop and high weight-reducing hole used in the hy-draulic support for thin coal seam produced misalignment,ball-socket surface and socket mouth deformation,large intercept after draft,obvi-ous sudden change in cross-sectional area,large forming loading and low mold life easily during forging process,a new forging method was proposed.By adopting curved surface parting,oblique placement of mold cavity,gradient drafting,reduction of mold closing height and so on,the forging of this type for pillar nest and the smooth ejection of mold were realized.The results show that the purpose of improving forg-ings quality,reducing machining allowance and number of strokes,shortening strike time,enhancing productivity and reducing production cost was achieved by reasonable design of mold structure,mold material and heat treatment hardness.Through a long time research on the forming process of large-scale die forgings,the process parameters of large-scale forgings that are not in the national standards of forging in-dustry were summarized.