Дослідження нового способу кування великих злитків на основі осадження заготовок з уступами

Abstract

Markov O. E., Khvashchynskyi A. S., Musorin A. V., Lycenko A. A., Molodetskie V. V.  Study of new forging process of ingots based on deformation of workpieces with conical ledges

New process of workpieces upsetting with ledges has been developed and studied in the work. Workpiece's ratio length before deformation was H / D = 3.0. Strain and stress condition has been studied to find the sign and level of compress stresses in a forged piece. Moreover, the parameter of the stress state in the zone location of the cavities has been evaluated. The closing degree of axial cavities has been determined. This parameter has been found for different heights and diameters. It has been found that the workpiece upsetting with ledges leads to a uniform stress into the forged-piece body. During deformation on the perifical surface and in the central zone there is compress stress due to the formation forged-piece with the concave size. Moreover, there is a closing of the internal cavities and recess on the lateral surface. Effective geometrical parameters of the initial workpiece have been found. It has been established that a decrease in the diameter and an increase in the height of the ledges leads to a decrease in the convexity in the studied range of workpiece sizes. The convexity increases as the diameter of the ledges decreases. The “barrel” is leveled and during subsequent upsetting, the side surface of the workpiece takes on a shape close to cylindrical. The relative diameter and height of the protrusions should be d/D = 0.5…0.7 and h/D = 0.4…0.6, respectively, to close defects during upsetting. The effective degree of deformation is 50 %. Determined relations have been checked out by experimentally in the process of the ingot`s forging weight equal to 66.5ton. Obtained practical results confirms the FEM results. The results of the investigation have been introduction in the manufacturing.