Research On Copper Water Box Closed-Die Upsetting-Extrusion Process Of Turbine

Water box component is one of the most important components of turbine. Because of the high conductivity requirement, red copper should be used. This component must have high forming quality and is not able to exist defects that lead to leaking water and gas. Water box formed by conventional casting method always has many defects in its microstructure which will have short working life. Closed-die upsetting-extrusion process is a suitable method to forming this kind of component because component formed by this process meet the quality requirement and it also saves materials and product period and so has low cost. It is urgent need to solve the problem of how to produce it efficiently and economically.In this paper, multi-stage upsetting-extrusion process is determined through analyzing the characteristic of water box, combining the technique of red copper forging. Also the die is designed. Metal flowing rules, stress and strain distributions and the influence of die dimensions on metal flowing in water box component multi-stage upsetting-extrusion process is investigated by using numerical simulation and experimental method. On the basis of above, the forming parameters are optimized, stress distribution of the mold is obtained, and research on the optimized project of mold structure has been done.According to the process, the experiment of water box is accomplished, which turns out the correctness of numerical simulation and feasibility of the process.The process of water box that this paper conducts offers theoretical basis and technological parameters for practical production, and makes it possible produce high-quality water box. It also provides experience for forming the similar complex parts.