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多向模锻是现阶段大口径阀门阀体生产工艺。多向模锻冲头存在过早断裂以及表面压溃变形等问题,冲头使用寿命较短。锻件金属流动的不均匀性是导致冲头受力偏载发生断裂的首要原因,冲头材料热强性较低导致表面发生压溃变形。该文通过优化模具设计改善锻件金属流动趋势,改变冲头与压机的连接方式以减少冲头根部应力集中,采用FGH96高温合金作为锻压冲头材料,提高冲头的高温变形抗力。工艺分析及实验表明:优化模具圆角,水平冲头表面采用光滑化设计,可有效降低冲头连接部位应力集中水平,防止冲头在生产中发生断裂;采用FGH96材料制造的水平冲头在连续生产时,冲头应力水平低于屈服强度,冲头未发生压溃现象。所设计的锻压3吋(7.62cm)旋塞阀用压机水平冲头,经现场实验,其冲压次数达到100件,未发生断裂及表面压溃,冲头的使用寿命有较大幅度延长。
Multi-die forging is the current large-caliber valve body production process. Multi-directional forging punch there premature rupture and the surface crush deformation and other issues, short life of the punch. The inhomogeneity of the metal flow in the forging is the primary reason for the rupture of the punch due to the partial load. The lower thermal strength of the punch material causes the surface to crumble and deform. This paper improves the metal flow tendency of the forging by optimizing the die design, changing the connection between the punch and the press to reduce the stress concentration in the root of the punch. The FGH96 superalloy is used as the forging punch material to improve the high temperature deformation resistance of the punch. Process analysis and experiments show that: Optimize the mold fillet, horizontal punch surface with a smooth design, which can effectively reduce the stress concentration of punch connection parts to prevent the punch in the production of fracture; using horizontal punch FGH96 material in a row Production, punch stress level below the yield strength, punch did not collapse phenomenon. The designed forging 3 inch (7.62cm) plug valve with a horizontal punch, the field experiment, the stamping times to 100, no fracture and surface crush, the life of the punch is more substantial extension.