Transactions of Materials and Heat Treatment

Title：Process technology on extra-large hydropower stepped flange forgings

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ClassificationCode：TG316

year,vol(issue):pagenumber：2021,46(3):37-42

Abstract：

The extra-large hydropower stepped flange forgings with Ф4160 mm have heavy tonnage, large specifications, large flange diameter and difference in adjacent cross-sections, and it is difficult to guarantee the final sizes using traditional method of ingot blanking, mandrel drawing with clamping table and reaming. Therefore, a new control method of “solid step billet+stepped reaming” was proposed for the first time by comprehensive analysis of key forming methods and control difficulties of the extra-large hydropower stepped flange forgings to innovate the forging process, it was determined that the solid billet was forged on the clamping table with pliers, and then the flattening process of end surface was added after blanking. In addition, the reduction of stepped reaming was controlled between 30 and 45 mm, and the hole shrinkage process was added after reaming for each fire. Combined with the process analysis, the analysis models of plastic finite element and structural finite element were established, and the metal flow laws, the metal flow rate and the metal flow velocity difference of each part for solid billet and stepped reaming were simulated and analyzed to predict the new process parameters, the process control, the effect and quality of solid billet and stepped reaming. At last, the rationality of process parameters and forming process were verified by production test.

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李昌义(1981-)，男，博士，高级工程师 E-mail：change371@163.com 通讯作者：胡振志（1981-），男，硕士，工程师 E-mail：zhenzhi401@163.com

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