A new method of plate forging with V-shaped dies is proposed. The deformation state of a metal workpiece during forging has been investigated. The proposed method of forging increases the uniformity of the strain distribution with a high level of strain in the workpiece. The values of angles for V-shaped dies range from 120°to 140°. This range of die angles is the most rational from the standpoint of strain distribution uniformity and maximum widening. V-shaped die usage for plate forging leads to an increase in widening coefficient of 35 % in comparison with forging with flat dies. This forging technique provides the possibility of eliminating the operation of billet upsetting during plate forging. V-shaped die usage for plate forging also results in a decrease in deformation load in comparison with flat die forging. The scheme of plate forging by V-shaped dies results in the formation of an irregular compression state in the axial zone. It leads to the closing of defects during forging. The new technology of plate forging with V-shaped dies was tested under industrial conditions. The forged piece has satisfied the requirements of the customer's technical criteria. The ultrasonic check results have shown that the application of the proposed technology provides an increase in metal continuity within the central zone of the forged piece. The experimentally derived forging results have confirmed that upsetting operations can be eliminated, and as a result, energy expenditures and the overall cycle time of the forging operation have been reduced by 15 %.
Quantity of massive parts produced from an ingot is increasing today. It is caused by increasing of a massive equipment powerful. However, the quality of produced forging parts does not corresponds to customer`s requirements.Poor quality of the produced forging parts is caused by low quality of forging ingots.Defects of ultrasonic test after forging of the massive forging parts equal to 10%. The defects after ultrasonic test are caused by upsetting operation of the ingots with no equal internal structure. As a result, internal structure is processed unevenly and insufficiently. Increasing of the ingot internal defects occurs during upsetting operation of billets by flat deformationtools.The purpose of this work is establishing the rational geometry of billets with conical faces which guarantee the welding of the axial defects during upsetting operation.Rising diameter of conical face provide decreasing of defect welding degree. The toll conical faces rise the degree of thewelding defects. It was established that decreasing of the diameter and rising of the height the conical faces provide to reduction of convexity of the workpiece. In the initial step of the upsetting operation the “double convexity” is occurred. The convexity is growing at the diameter decrease of the conical faces. The “double convexity” levels out and the external surface of the workpiece obtains the nearly cylindrical shape in the finish upsetting. The relative height and diameter of the conical faceshave to be 0.4...0.6 and 0.5...0.7 respectively concerning the welding defects and equable distribution of the deformations at the upsetting. Obtained data of the upsetting in the manufactured conditions verified the established technological recommendations ofthe workpiece shape and dimensions obtained by theoretical modeling.
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