张大伟.大型模锻件低能耗省力整体成形研究现状、挑战与展望[J].精密成形工程,2025,17(4):10-34.
ZHANG Dawei.Current Status, Challenges and Prospects of Integral Forming with Low Energy Consumption and Less-force for Heavy Closed-Die Forging[J].Journal of Netshape Forming Engineering,2025,17(4):10-34. |
| 大型模锻件低能耗省力整体成形研究现状、挑战与展望 |
| Current Status, Challenges and Prospects of Integral Forming with Low Energy Consumption and Less-force for Heavy Closed-Die Forging |
| 投稿时间：2025-02-07 |
| DOI：10.3969/j.issn.1674-6457.2025.04.002 |
| 中文关键词: 断续局部加载 大锻件 省力成形 材料流动 液压机 |
| 英文关键词: intermittent local loading heavy forging less-force forming material flow hydraulic press |
| 基金项目:国家自然科学基金(52375378);金属成形技术与重型装备全国重点实验室开放课题(S2308100.W12) |
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| 中文摘要: |
| 随着航空、航天领域整体成形的关键承力构件的尺寸不断加大，所需成形设备吨位以及单件产品的能耗、成本居高不下。大型模锻件的低能耗省力成形可从变形抗力、承载变形面积、工艺过程3个方面发展实施技术。局部加载能减小承载变形面积，控制应力状态，降低接触面压力，同时具有一定柔性成形能力，便于调控材料流动，在成形过程中实现材料体积再分配，从而有效降低成形载荷，并可降低制坯到终锻全制造流程的能耗，为采用难变形材料的大型模锻件低能耗成形制造开辟了一条可行途径。其实现方式多样、适用对象迥异，对设备功能要求不同，短流程、低成本绿色制造的推广应用仍面临挑战。本文归类了锻造过程中的能量消耗，总结了锻造力的影响因素，讨论了低能耗省力成形的实施途径;评述了现有3类局部加载整体成形大型复杂构件的方法及其应用，特别是对筋板类构件成形制造的工业应用;着重阐明了采用模具分区方式进行局部加载成形过程中的材料流动特征，从理论上阐明了摩擦对局部加载成形中材料流动的正面影响，指出了成形过程中材料流动控制方法;讨论了大型复杂构件局部加载成形实现设备的挑战及要求，指明了大型模锻件断续局部加载成形进一步应用发展需要解决的关键技术问题及潜在的应用场景。 |
| 英文摘要: |
| In the aviation and aerospace industries, the size of key load-bearing component manufactured by integral forming process is increasing. The manufacture for it needs heavy press with more tonnage, and the energy consumption and cost per component are high. Low energy consumption and less-force forming technology of heavy closed-die forging can be developed from the following aspects:deformation resistance, bearing deformation area and forming process. The local loading process can reduce the bearing deformation area, control the stress state and reduce the pressure on the contact surface. It has a flexible forming capability, and is easy to control the material flow, realizes the second metal distribution during forming process, effectively reduces the forming load and can reduce the energy consumption of the through manufacturing process from preforming to finish forging. However, the local loading can be implemented in diverse ways and be applied to different components, and then the functional requirements of the equipment are different. The promotion and application with short-process and low-cost green manufacturing are still facing challenges. The energy consumption in forging process were classified, the factors influencing the forging force were summarized, and the implementing ways of forming process with low energy consumption and less-force were discussed. Three categories of integral forming methods by local loading and their applications for large-scale complex components were reviewed, especially for the industrial applications of rib-web components. The material flow characteristics in local loading process by using the die partition method were illuminated, and the positive effect of friction on material flow in local loading process was expounded theoretically, and then control methods of material flow in local loading process were pointed out. The challenges and requirements of the local loading forming equipment for large-scale complex components were discussed. Some proposals and potential application for the further study in intermittent local loading forming of heavy closed-die forging are presented in detail. |
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