Background and overall idea of forging die design
Forging die design is by no means a simple task. It is a carefully carried out work to achieve a specific deformation process. In the actual production process, we cannot act blindly, but need to make comprehensive and detailed considerations. First of all, it is necessary to accurately determine the deformation process and the applicable die - forging equipment according to various characteristics of the parts, such as size, specific shape, strict technical requirements, scale of production batch and the actual situation of the workshop. Only by doing these preparatory work well can the subsequent forging die design be more targeted and scientific.
Specific procedures for forging die design
1. Analysis of the finished product shape
Conduct an in - depth analysis of the shape of the finished product, which is essentially an in - depth study of the forging processability of the finished product. By comprehensively understanding the shape characteristics of the finished product, we can predict the problems that may be encountered during the forging process, so as to plan countermeasures in advance and lay a solid foundation for the subsequent design work.
2. Design the forging drawing based on the part drawing
The forging drawing plays a crucial and significant role in the entire production process. It serves as the key basis for numerous subsequent tasks. The machining workshop will design jigs and fixtures with reference to the forging drawing. Meanwhile, it is also an important criterion for determining the size of the original blank and inspecting the forgings. When formulating the forging drawing, the following aspects of work need to be completed:
Determine the parting surface: The position and shape of the parting surface directly affect the forming quality and production efficiency of forgings. A reasonable parting surface can make it easier for the forging to be ejected from the die, reduce die wear, and improve production stability.
Clarify the machining allowance, tolerance and surplus blocks: Accurately determining the machining allowance, tolerance and surplus blocks can ensure that the forgings meet the design requirements while avoiding material waste and improving the economic efficiency of production.
Set the die forging draft: The reasonable setting of the die forging draft helps the forging to be formed and demolded smoothly in the die, reduces the friction between the forging and the die, and improves the service life of the die.
Determine the fillet radius: A suitable fillet radius can improve the stress distribution of the forging, avoid defects such as cracks during the forging process, and enhance the quality and performance of the forging.
Determine the punching flash: The shape and size of the punching flash have an important influence on the punching quality of the forging and subsequent processing, and precise design is required according to the specific situation.
Define the webs and ribs: Accurately determining the shapes and dimensions of the webs and ribs can ensure the structural strength and stability of the forging and meet the requirements of actual use.
3. Determine the manufacturing method and equipment parameters
It is necessary to clarify the manufacturing method, such as the choice of how many pieces are produced in one mold. This requires comprehensive consideration of factors such as production efficiency and mold cost. At the same time, it is necessary to accurately calculate the tonnage of the required equipment to ensure that the equipment can meet the pressure requirements during the forging process and guarantee the smooth progress of production.
4. Design the die forging steps and die cavities
The design of die forging steps and die cavities is the core part of forging die design. There are strict requirements for its design sequence. First, design the finish forging die cavity. The design of the finish forging die cavity should ensure that the forging can meet the final dimensional and shape requirements. Then, design the pre - forging die cavity and the blank - making die cavity. The pre - forging die cavity can improve the metal flow and reduce the wear of the finish forging die cavity, while the blank - making die cavity provides a suitable blank shape for subsequent forging.
5. Design the forging die body
The design of the forging die body (or die assembly) should take into account the rationality and stability of its structure. A reasonable die body design can ensure that the die can withstand huge pressure without deformation during the forging process, and at the same time facilitate the installation and adjustment of the die.
6. Design trimming dies and punching dies
The design of trimming dies and punching dies should match the shape and size of the forgings to ensure that the excess flash can be accurately removed and the punching operation can be completed, thereby improving the precision and surface quality of the forgings.
7. Design the correction mold as needed
According to the needs of actual production, sometimes it is also necessary to design a correcting die. The correcting die can perform the final shaping of the forging to ensure that the dimensional accuracy and shape of the forging meet the design requirements.
8. Determine the mold material
The selection of mold materials directly affects the strength, hardness, wear resistance and service life of the mold. It is necessary to select appropriate mold materials according to the requirements of the forging process and the working conditions of the mold, and reduce production costs on the premise of ensuring the performance of the mold.
General requirements for forging die design
1. Ensure the accuracy of forgings
When designing forging dies, the primary goal is to ensure that forgings meeting the dimensional accuracy requirements can be obtained. This requires precise calculations and strict control at every stage of the die design to ensure that the dimensional deviations of the forgings are within the allowable range.
2. Have sufficient strength and service life
Forging dies have to withstand huge pressure and impact force during the working process, so they must have sufficient strength and a long service life. Reasonable die structure design and selection of high - quality die materials are the keys to ensuring the strength and service life of the dies.
3. Ensure the work is stable and reliable
The forging die should be stable and reliable during operation to avoid problems such as die shaking and misalignment during the forging process, ensuring the continuity and stability of production.
4. Meet the productivity requirements
On the premise of ensuring the quality of forgings, the design of forging dies should meet the requirements of productivity. By optimizing the die structure and process flow, the forging time can be reduced and the production efficiency can be improved.
5. Easy to operate
The designed forging die should be easy for operators to handle, reduce labor intensity and improve operation safety. For example, the die should be easy to load and unload, and the layout of operation buttons should be reasonable.
6. Simple to manufacture
Simple mold manufacturing can reduce production costs and manufacturing cycles. During the design process, simple structures and processes should be adopted as much as possible to avoid complex processing procedures.
7. Easy to install, adjust and repair
The installation, adjustment and maintenance of forging dies should be simple, which can reduce the equipment downtime and improve production efficiency. Meanwhile, a die structure that is easy to maintain can also reduce maintenance costs.
8. Save materials
On the premise of ensuring the strength of the mold, efforts should be made to save forging die materials as much as possible. Through the reasonable design of the mold's size and structure, the waste of materials should be reduced and the utilization rate of materials should be improved.
9. Meet the equipment specifications
The external dimensions of the forging die should comply with the technical specifications of the equipment to ensure that the die can be smoothly installed on the equipment and work in coordination with other components of the equipment.