Wall-type Flash Cave In Complex Forgings Research And Application

With the transformation and upgrading of global manufacturing industry towards precision production,forgings with high mechanical properties,complex cross-section shape and high precision size are increasing year by year.There are many kinds of the bridge size design methods of the forging die.The flash cave of the forging die can be divided into three types: typical flash cave,wedge flash cave and expansion flash cave.When the dimension parameters of the flash land are the same,the influence of different flash cave on the forging forming is also different.Complex forgings are difficult to fill and forge because of drastic changes in cross section,deep cavity at high point or too far end.The traditional flash cave structure has been difficult to meet the requirements of complex forging forming and production cost control.In order to solve the problems of forming difficulty and high cost of forgings,two schemes of typical flash cave and wall flash cave are compared from the aspects of forging quality and forging load.The advantages and disadvantages of setting wall flash cave on die are expounded.This paper focuses on the practical effect of applying wall flash cave structure to the die of complex forgings.Five typical forgings are selected from aviation,weapons,automobile,mining and high-speed railway industries,covering branches,ribs,webs,thin plates,long rods and hybrid structures.Wall-type flash cave structure is adopted for parts that are not easy to fill.Through the Vieregge.K design method formula,the reasonable parameter h is selected,and the corresponding flash caves of typical forgings are designed by combining the structural relationship of wall flash caves.Through Deform software simulation and actual production verification,the design structure can meet the product quality requirements of forging production,improve material utilization and reduce production costs.The results show that in the die design of complex forgings,the wall flash cave structure can not only greatly improve the ability of filling the cavity with metal,but also solve the defects of non-ferrous metal forgings such as through-flow and folding.This flash cave structure can be extended to the design of forming die for all complex forgings.