Process And Die Design And Metal Deformation Behaviers Study Of All Fiber Forging Of Large Hooks

The large hook is an important fetch device for lifting equipments widely used in transportation, construction, transportation, shipping, and other fields. The structure strength, safety performance and service life play an important rolein the lifting operation. Because hooks need long-term work under heavy loads, their strength, hardness and impact toughness must satisfy the requirements. Hooks production adopts the method of forging process including free forging and die forging. Traditional forging process of the large hooks includes many problems, such asthe low utilization of materials, the long-termproduction cycle, the cut-off fiber forging, affecting the service life of the hooks and costsofforging production.For above problems, this paper analyzed the current situation of large double hooks production technology in detail, developed a new type of all fiber forging process for large hookforming technology, established forging process numerical simulation models, analyzed the law of material deformation, optimized the preform shapes and preform die shapes, designed and developed the all fiber forging process and dies for three types of hooks, eventually improved material utilization and realized the purpose of all fiber forging.This paper aimed at the production requirement of large hooks with the forging process, combined with characteristics of all fiber forging, developed a new type of all fiber forging process for large hook, including blanking, upsetting, indentation, split mouth, long pull hook and bar of curving, hook tip, finish forging, cutting flash, thermal correction. According to the new forging process, for three respective types of large hooks,150T,100T and 100T50#, this paper designed the forging process, drawed the cold and hot forging maps, determined the blank weight and size.This paper designed preform shape of membranes of three types hooks, designed the "T" preform shape and size for each type hook respectively, built the preforging process, hook tips bending process and finish forging thermal coupled finite element numerical simulation models of each type of hooks, analyzed the various deformation laws of material in the process of forging.According to the material flow laws of the three types of hooks in forging process, optimized the "T" preform size and the hook tips curve shapes of membranes, ensured that the hook tips’ shapes after preforging could satisfy the demands of volume distribution, proved by finite element numerical simulation analysis, contrasted material filled in the final forging die cavity and flash distribution, ensured the final forging with no cavity folding and reasonable flash distribution, material utilization rate was above 70%,100T50# was 85%. Finally, the summary of forging process and die design method for this series of hooks was given, and provided the technical guidance for the other similar type of hooks in forging technology and die design.