Patent Application
20100307216
1. Field of the Technology
The present disclosure relates to equipment and techniques for forging die heating. The present disclosure more specifically relates to equipment and techniques for heating a forging surface of a forging die.
2. Description of the Background of the Technology
A work piece, such as an ingot or a billet, for example, can be forged into a particular configuration or shape using a forging die. Forging dies can comprise open-faced forging dies, closed-faced or “impression” forging dies, or other suitable forging dies. Most open-faced forging dies can comprise a first or a top portion and a second or a bottom portion. In general, the bottom portion can act as an “anvil” or a stationary portion, while the top portion can act as the “hammer” or a movable portion as it moves toward and away from the bottom portion. In other open-faced forging dies, both the top and the bottom portions can move toward each other or, in still other configurations, the bottom portion can move toward a stationary top portion, for example. The movement of the top or bottom portions of the forging die can be accomplished through the use of pneumatic actuators or hydraulic actuators, for example. In any event, the top and bottom portions of the forging die can be disposed in an open position, where they are spaced a suitable distance from each other, and in a closed position, where they contact or nearly contact each other.
During the forging process, a portion of the work piece can be positioned between the top portion and the bottom portion of the forging die and forged by force applied by the top portion and/or the bottom portion. Applying such force to the work piece can change the structural properties and/or the crystalline structure of the work piece, such as through work hardening, thereby possibly developing weak spots in the work piece. Work hardening, for example, may be inhibited if the work piece is heated to a suitable temperature prior to or during the forging process. Heating of the work piece can make the work piece more malleable such that it can be forged using less force applied by the top and/or the bottom portions of the forging die. Depending on the composition of the work piece, the work piece can be heated to a temperature in the range of 1800-2100 degrees Fahrenheit, for example, prior to being forged, to facilitate forging of the work piece. As can be seen, various benefits may be achieved by heating the work piece prior to and/or during forging.
In addition to the heating of the work piece prior to and/or during forging, in some instances, the top and/or bottom portions of the forging die can also be heated to reduce or minimize any temperature differential between the heated work piece and the top and bottom portions of the forging die. Through such heating, surface cracking of the work piece during forging can be reduced relative to forging using a forging die at ambient temperature (20-25 degrees Celsius). For example, if a region of a work piece heated to a temperature of 1800-2100 degrees Fahrenheit contacts a forging die at ambient temperature, the significant temperature differential reduces the temperature of the work piece region and adjacent regions. The significant temperature differential can create mechanically weak regions within the work piece that may make the work piece unsuitable for its intended application. Further, in some instances, the significant temperature differential between forging die and work piece can lead to inclusions in the work piece caused by non-uniform cooling of the work piece during and after forging if the region of the work piece contacted by the ambient temperature forging die cools faster than the rest of the heated work piece.
In an attempt to minimize these negative consequences, referring to
Such preheating of the forging die, although helpful in the forging process, can lead to non-uniform heating of the forging die 4 or a forging surface 5 of the forging die 4, again possibly resulting in inclusions or weak spots in the work piece where the forging die 4 contacts and cools the work piece. Another issue with the above-described preheating practice is that, even though the forging die 4 can be heated to about 600-800 degrees Fahrenheit, there can still be a substantial temperature differential between the work piece, which may be at forging temperatures of about 1800-2100 degrees Fahrenheit, and the forging die 4. The existence of a significant temperature differential between the work piece and the forging surface 5 can sometimes lead to surface cracking of crack-sensitive alloy work pieces, such as Alloy 720, Rene '88, and Waspaloy, for example. Further, the non-uniform cooling produced by temperature differentials can, in some instances, cause inclusions or weak spots within work pieces of these alloys.
Given the drawbacks associated with conventional forging die pre-heating techniques, it would be advantageous to develop alternative pre-heating techniques.
According to one non-limiting aspect of the present disclosure, an embodiment of a forging die heating apparatus comprises a burner head comprising a plurality of flame ports. The burner head is oriented to compliment an orientation of at least a region of a forging surface of a forging die. The burner head is configured to receive and combust a supply of an oxidizing gas and a supply of a fuel and produce flames at the flame ports. The plurality of flame ports are configured to impinge the flames onto at least a region of the forging surface of the forging die to substantially uniformly heat at least a region of the forging surface of the forging die.
According to another non-limiting aspect of the present disclosure, an embodiment of a forging die heating apparatus comprises a burner head comprising a plurality of flame ports. The burner head is configured to be at least partially conformed to an orientation of a region of a forging surface of a forging die. The burner head is configured to receive and combust a supply of an oxidizing gas and a supply of a fuel and produce flames at the flame ports. The plurality of flame ports are configured to impinge the flames onto and substantially uniformly heat the region of the forging surface of the forging die.
According to yet another non-limiting aspect of the present disclosure, an embodiment of an open-faced forging die heating apparatus comprises a burner comprising a manifold configured to receive a supply of an oxidizing gas and a supply of fuel and a burner head. The burner head comprises a first portion comprising a first set of flame ports comprising at least two flame ports. The first set of flame ports are in fluid communication with the manifold such that the first set of flame ports are configured to impinge at least two flames onto a first region of a forging surface of a forging die. The burner head further comprises a second portion comprising a second set of flame ports comprising at least two flame ports. The second set of flame ports are in fluid communication with the manifold such that the second set of flame ports are configured to impinge at least two flames onto a second region of the forging surface of the forging die, wherein an orientation of the burner head conforms to an orientation of at least the first region of the forging surface of the forging die.
According to still another non-limiting aspect of the present disclosure, an embodiment of a forging die preheating apparatus comprises a burner head comprising a first flame port, a second flame port, and a third flame port. The second flame port is substantially the same distance from the first flame port and the third flame port. The burner head is configured to receive and combust a supply of an oxidizing gas and a supply of fuel to produce a flame at each of the first flame port, the second flame port, and the third flame port. Each of the first flame port, the second flame port, and the third flame port are configured to impinge the flames onto at least a region of a forging surface of a forging die and preheat the region of the forging surface prior to forging a work piece with the forging die.
According to still another non-limiting aspect of the present disclosure, an embodiment of a method of heating a forging die comprises positioning a burner head comprising at least two flame ports in proximity to a region of a forging surface of the forging die. The method further comprises supplying an oxy-fuel to the at least two flame ports and combusting the oxy-fuel at the at least two flame ports to produce an oxy-fuel flame at each of the at least two flame ports. The method further comprises impinging at least two of the oxy-fuel flames onto the region of the forging surface of the forging die and substantially uniformly heating the region of the forging surface of the forging die.
According to still another non-limiting aspect of the present disclosure, an embodiment of a method of preheating an open-faced forging die comprises positioning a burner head comprising at least two flame ports in a location at least partially intermediate a first forging surface of the forging die and a second forging surface of the forging die. The burner head is oriented to at least partially conform to an orientation of at least one of the first forging surface and the second forging surface. The method further comprises supplying a fuel to the at least two flame ports, combusting the fuel to produce a flame at each of the at least two flame ports, and impinging at least two of the flames onto at least one of the first forging surface and the second forging surface.
According to yet another non-limiting aspect of the present disclosure, an embodiment of a forging die drift hard-stop system for a forging die apparatus including a top forging portion attached to a cross head and a bottom forging portion is provided. The forging die drift hard-stop system comprises an arm comprising a first end and a second end. The second end of the arm is pivotably attached to a portion of the forging die apparatus and a spacer is attached to the first end of the arm. The arm is movable between a first position, where the spacer is free from engagement with a portion of the forging die apparatus and a portion of the cross head, and a second position, where the spacer is engaged with the portion of the forging die apparatus and the portion of the cross head to inhibit movement of the top forging portion toward the bottom forging portion.
According to still another non-limiting aspect of the present disclosure, an embodiment of a forging die heating apparatus is provided. The forging die heating apparatus comprises an arm and a burner head movably attached to the arm. The burner head is configured to be moved between a first position relative to the arm and a second position relative to the arm. The forging die heating apparatus further comprises a plurality of burner nozzles positioned on the burner head and at least one assembly in fluid communication with the plurality of burner nozzles. The at least one assembly comprises an air aspirator configured to allow air to enter the burner head and an orifice configured to allow a combustible fuel to flow therethrough.
Features and advantages of the apparatus and methods described herein may be better understood by reference to the accompanying drawings in which:
The reader will appreciate the foregoing details, as well as others, upon considering the following detailed description of certain non-limiting embodiments of apparatuses and methods according to the present disclosure. The reader also may comprehend certain of such additional details upon carrying out or using the apparatuses and methods described herein.
In the present description of non-limiting embodiments, other than in the operating examples or where otherwise indicated, all numbers expressing quantities or characteristics of elements, ingredients and products, processing conditions, and the like are to be understood as being modified in all instances by the term “about”. Accordingly, unless indicated to the contrary, any numerical parameters set forth in the following description are approximations that may vary depending upon the desired properties one seeks to obtain in the apparatuses and methods according to the present disclosure. At the very least, and not as an attempt to limit the application of the doctrine of equivalents to the scope of the claims, each numerical parameter should at least be construed in light of the number of reported significant digits and by applying ordinary rounding techniques.
The present disclosure, in part, is directed to improved designs for forging die heating apparatuses configured to heat a forging die or all or a region of a forging surface of a forging die. In one non-limiting embodiment, referring to
Prior to forging, it may be desirable to heat or preheat (hereinafter the terms “preheat” or “preheating” will also encompass the terms “heat” or “heating”, and vice versa) all or a region of the first forging surface 16 and/or the second forging surface 18 of the forging die 10. Such heating can reduce a temperature differential between a heated work piece and the first and/or the second forging surfaces 16 and 18. Convention preheating techniques using a single torch, however, can require hours to heat a forging die given that the techniques involve preheating only a small area of a side surface of the forging die at any one time. Using such convention preheating techniques can also result in non-uniform heating of the first and second forging surfaces 16 and 18. As a result, when the forging surfaces 16 and 18 contact the work piece, a first region of the forging surfaces 16 and 18 may be a first temperature and a second region of the forging surfaces 16 and 18 may be a substantially different second temperature, thereby possibly resulting in surface cracking and/or non-uniform cooling of the work piece, for example. Further, such conventional preheating techniques may not preheat the first and/or second forging surfaces 16 and 18 to a temperature substantially the same as the heated work piece, thereby allowing a significant temperature differential to exist between the work piece and/or the first and second forging surfaces 16 and 18 of the forging die 10. If a significant temperature differential exists, the portion of the work piece contacting the forging surfaces 16 and 18 may be cooled too quickly, which can lead to surface cracking and/or inclusions within the work piece, for example.
To provide uniform, or substantially uniform, preheating of at least a region of the first and/or the second forging surfaces 16 and 18, an improved forging die heating apparatus 20 is provided. Hereinafter the terms “forging surface” or “forging surfaces” may comprise regions of both the top and bottom portions of the various forging dies. As shown in
In one non-limiting embodiment, aspects of which are schematically illustrated in
In one non-limiting embodiment, the burner head 22 can be in fluid communication with one or more mixing devices or torches 24 configured to receive the supply of the oxidizing gas and the supply of the fuel and provide a mixed supply of the oxidizing gas and the fuel to the burner head 22 via conduit 31. Although oxidizing gas and fuel supply lines are not illustrated in
In one non-limiting embodiment, referring to
In one non-limiting embodiment, the burner head 22 can be comprised of a highly heat conductive material, such as brass or copper, for example. The burner head 22 can also comprise one or more mixing chambers or manifolds (referred to collectively as “manifold”) configured to receive a mixed supply of a fuel, such as natural gas, methane, and/or propane, for example, and an oxidizing gas, such as air or pure oxygen, for example. The one or more manifolds can be in fluid communication with various flame ports 26 of the burner head 22 such that the mixed supply can be provided to the flame ports 26 and combusted at the flame ports 26. At least one passage or channel, configured to receive a cooling liquid, vapor, and/or gas can at least partially surround, be positioned adjacent to, and/or be positioned proximate to, the one or more manifolds. Of course, the hottest portion of the burner head 22 is usually the portion of the burner head 22 comprising the flame ports 26. One object of the cooling system is to extract any excessive heat in the walls of the one or more manifolds and/or the walls of the flame ports 26 to prevent, inhibit, or at least minimize the chance of, internal explosions and/or combustion within the one or more manifolds of the burner head 22 owing to the heat within the burner head 22. In some circumstances, these internal explosions and/or combustion can cause the burner head 22 to operate in inefficiently. Thus, by providing distinct manifolds and passages or channels for the fuel and oxidizing gas mixture and the liquid, respectively, along with the highly heat conductive materials of the burner head 22, heat can easily be dissipated from the walls of the one or more manifolds and/or the walls of the flame ports 26.
In non-limiting exemplary embodiments, the above-referenced cooling system is illustrated in
Although not illustrated or described with respect to each non-limiting embodiment of the present disclosure, it will be understood that a liquid cooling system, or other cooling system, can be used with each non-limiting embodiment of the present disclosure.
Further to the above, referring to
In one exemplary non-limiting embodiment, the flame ports 26 can have a 0.030 inch diameter or a diameter in the range of 0.015 inches to 0.1 inches, for example. Smaller flame ports can be spaced one half of one inch from other flame ports on the surface 28 of burner head 22, for example, to provide uniform, or substantially uniform, preheating of the forging surface(s) 16 and/or 18 of the forging die 10. Larger flame ports can be spaced one inch from each other, for example, to provide uniform, or substantially uniform, preheating of the forging surface(s) 16 and/or 18 of the forging die 10. Of course, other suitable flame port spacing is within the scope of the disclosure. In one non-limiting embodiment, the flame ports 26 can comprise any suitable shape such as circular, ovate, and/or conical, for example. In other non-limiting embodiments, as will be apparent to those of ordinary skill in the art upon consideration of the present disclosure, any other suitable flame port diameters, shapes, configurations, and/or flame port spacing can be used. In one non-limiting embodiment, the substantially uniformly spaced flame ports can each produce a substantially uniform flame to better provide for substantially uniform preheating of one or more forging surface, for example. In one non-limiting embodiment, the various flame ports 26 can be cleaned after one or more uses, such that none of the flame ports 26 remain or become blocked by combustion residue, debris, or other materials produced by the forging die preheating process. In one non-limiting embodiment, a drill bit, such as a number 69 drill bit, for example, may be used to clean the flame ports 26. In other non-limiting embodiments, an automated computer numerical controlled (“CNC”) machine can be programmed to clean the flame ports 26, for example.
With reference to FIGS. 2 and 5A-5C, in one non-limiting embodiment, the burner head 22 can comprise a hollow manifold 21′, 21″, or 21′″ (hereafter “21”) configured to mix the supply of the oxidizing gas with the supply of the fuel and/or receive a mixed supply of the oxidizing gas and the fuel from one or more mixing torches 24. The manifold 21 can be in fluid communication with the plurality of flame ports 26 such that it can deliver the mixed supply of the oxidizing gas and the fuel to the flame ports 26 for combustion at the flame ports 26. The passages 23′, 23″, and/or 23′″, described above can extend through and/or surround portions of the manifold 21, for example, for cooling of the burner head 22 through heat transfer to the liquid, vapor, and/or gas flowing through the passages 23′, 23″ and/or 23′″. Although the manifold 21 is illustrated in fluid communication with the flame ports 26 on one surface 28 of the burner head 22, it will be apparent from the disclosure that the manifold can be in fluid communication with flame ports on each of two opposed surfaces of the burner head 22, for example. Further, while the manifold 21 is not illustrated and described with respect to each non-limiting embodiment described in the present disclosure, those of ordinary skill in the art will recognize that a manifold can be supplied in each burner head described herein. In one non-limiting embodiment, the burner head 22 can be configured to receive and combust the mixed supply of the oxidizing gas and the fuel from the manifold 21 to produce the flames 29 at the flame ports 26. The flames 29 can be used to preheat at least a region of at least the first forging surface 16 and/or the second forging surface 18 of the forging die 10.
In one non-limiting embodiment, referring to
In various non-limiting embodiments, and still referring to
Referring to
In one non-limiting embodiment, the first portion 232 of the burner head 222 can have a shape conforming to at least a region of a first forging surface 216 of the forging die 210, and the second portion 234 can have a shape conforming to at least a region of a second forging surface 218 of the forging die 210. The first portion 232 can be configured to receive and combust the mixed supply of the oxidizing gas and the fuel to produce a first set of at least two flames 229 at the first set of at least two flame ports 226. The first set of at least two flames 229 can be impinged on the first forging surface 216 of the forging die 210 through the first set of at least two flame ports 226 to heat the first forging surface 216. Likewise, the second portion 234 can be configured to receive and combust the mixed supply of the oxidizing gas and the fuel to produce a second set of at least two flames 229′ at the second set of at least two flame ports 226′. The second set of at least two flames 229′ can be impinged upon the second forging surface 218 of the forging die 210 through the second set of at least two flame ports 226′ to heat the second forging surface 218. In the present disclosure, the terms “impinge” or “impinged”, with reference to the various flames, can mean the flames actually contact a forging die surface or can mean that the flames do not actually contact a forging die surface but are positioned proximately close to the forging die surface to suitably convey heat to the forging die surface.
In one non-limiting embodiment, the first set of at least two flame ports 226 can comprise a plurality of uniformly, or substantially uniformly, spaced flame ports 226. Also, the second set of at least two flame ports 226′ can comprise a plurality of uniformly, or substantially uniformly, spaced flame ports 226′. The uniform, or substantially uniform, spacing of the flame ports 226 and 226′ can better promote uniform, or substantially uniform, preheating of the first and second forging surfaces 216 and 218 of the forging die 210. The uniform, or substantially uniform, spacing of the various flame ports optionally can be a feature of all non-limiting embodiments of forging die heating apparatuses according to the present disclosure. Similar to the non-limiting embodiments described above, a liquid, such as water, for example, can be provided to and removed from the burner head 222 via line 225 and/or other optional lines to cool the burner head 222 during heating of the first forging surface 216 and the second forging surface 218. In one non-limiting embodiment, a valve 233 can be positioned at one end of the line 225. The valve 225 can direct the liquid into and out of the first portion 232 and/or the second portion 234 of the burner head 222, for example.
In one non-limiting embodiment, referring to
Again referring to
In one non-limiting embodiment, the spacer 338 can be comprised of any suitable material having a strength sufficient to withstand the forces by relative movement of the top portion 312 toward the bottom portion 314 of the forging die 310. These materials can comprise, steel or cast steel, for example. In various non-limiting embodiments, more than one spacer 338 can be provided, for example. In such an embodiment, a first spacer 338 can be provided on a first side of the burner head 322 and a second spacer 338′ can be provided on a second side of the burner head 322. In certain other non-limiting embodiments, a plurality of spacers can at least partially surround the burner head 322 to suitably protect the burner head 322 from being crushed and/or damaged by the relative movement of the top and bottom portions 312 and 314 of the forging die 310 toward one another. In one non-limiting embodiment, the forging die heating apparatus 320 can comprise the spacer and/or the spacer can be integrally formed with, attached to, separate from, and/or operably engaged with the forging die heating apparatus 320 and/or the burner head 322, for example. In one non-limiting embodiment, the forging die heating apparatus 320 can also comprise a manual or automated actuation arm 339 configured to be used to move at least the burner head 322 into and out of a position intermediate the top portion 312 and the bottom portion 314 of the forging die 310.
In one non-limiting embodiment, referring to
In one non-limiting embodiment, referring to
In various non-limiting embodiments, referring to
Similar to that discussed above, referring to
In certain non-limiting embodiments, referring to
In one non-limiting embodiment, referring to
In one non-limiting embodiment, the forging die heating apparatus 520 can comprise a member 554 supporting the first portion 532 and a member 554′ supporting the second portion 534. The member 554 can be movably attached to the first portion 532 via a pivotable element 560 and, likewise, the member 554′ can be movably attached to the second portion 534 via a pivotable element 560′. Such attachment can allow the first portion 532 to move relative to the member 554 and/or the movable member 538, and can allow the second portion 534 to move relative to the member 554′ and/or the movable member 538. Such movement can be manually accomplished by an operator of the forging die heating apparatus 520, for example. In one non-limiting embodiment, the forging die heating apparatus 520 can be locked into place after being conformed to forging surfaces of the forging die using any suitable locking mechanisms known to those of ordinary skill in the art.
In one non-limiting embodiment, referring to
In one non-limiting embodiment, still referring to
In one non-limiting embodiment, referring to
In one non-limiting embodiment, referring to
In one non-limiting embodiment, the mixed supply of oxidizing gas and fuel supplied to the various flame ports can be at least partially comprised of an air-aspirated fuel, for example, and/or any other suitable oxidizing gas and/or fuel. The oxidizing gas is provided in the mixed supply of the oxidizing gas and the fuel to facilitate combustion of the fuel. In one non-limiting embodiment it may be desirable to achieve faster and/or higher temperature preheating of forging surfaces of forging dies. In such an embodiment, the supply of the oxidizing gas can be predominantly or substantially oxygen, and the supply of fuel can be any suitable fuel that can be combusted in the presence of oxygen, such as acetylene, propylene, liquefied petroleum gas (LPG), propane, natural gas, hydrogen, and MAPP gas (a stabilized mixture of methylacetylene and propadiene), for example. By combusting such a fuel with an oxidizing gas predominantly or substantially comprised of oxygen, faster and higher-temperature heating of the forging surfaces of the forging dies can be achieved relative to combusting the fuel using ambient air as the oxidizing gas. Given that ambient air comprises only about 21 volume percent oxygen, preheating techniques using air as the oxidizing gas to facilitate combustion of the fuel can increase the time required for preheating and reduce the temperature of the forging surface achieved through preheating. Using a mixed supply comprising an oxygen-combustible fuel and an oxidizing gas comprised predominantly of oxygen (referred to herein as an “oxy-fuel”), the various non-limiting forging die heating apparatuses and methods of the present disclosure can relatively rapidly (for example, in 5 to 10 minutes) preheat all of or a region of a forging surface of a forging die to temperatures in the range of 700° F. to 2000° F., for example. Such temperatures are significantly higher than temperatures achieved in certain conventional forging die preheating techniques. Additionally, the use of an oxy-fuel can significantly reduce the time required to preheat the forging dies and/or the forging surfaces of the forging dies to the required temperature and can achieve a higher temperature preheat, thereby eliminating or at least minimizing the temperature differential between a heated work piece and the forging surfaces.
In one non-limiting embodiment, the present disclosure, in part, is directed to a method of heating a forging die or at least a region of a forging surface of a forging die. The method can comprise positioning a burner head comprising at least two flame ports in proximity to at least a region of a forging surface of the forging die and supplying a fuel, such as an oxy-fuel, for example, and an oxidizing gas to the at least two flame ports. The oxy-fuel can then be combusted at the at least two flame ports to produce a flame, such as an oxy-fuel flame, for example, at each of the at least two flame ports. The at least two flames can then be impinged onto at least the region of the forging surface of the forging die to uniformly, or substantially uniformly, heat the region of the forging surface of the forging die.
In one non-limiting embodiment, the method can comprise using a burner head comprising a first portion comprising a first set of flame ports comprising at least two flame ports and a second portion comprising a second set of flame ports comprising at least two flame ports. The method can further comprise moving at least one of the first portion and the second portion relative to a forging surface of a forging die. As such, an orientation of at least the first set of flame ports can be at least partially conformed to an orientation of a region of the forging surface of the forging die. In other non-limiting embodiments, the method can comprise using a burner head comprising a first portion comprising a first set of flame ports comprising at least two flame ports and a second portion comprising a second set of flame ports comprising at least two flame ports. The method can further comprise moving the burner head from a first configuration to a second configuration relative to the forging surface of the forging die using an actuator operably engaged with the burner head. As such, an orientation of at least the first set of flame ports can be at least partially conformed to an orientation of a region of the forging surface of the forging die. The method can further comprise using a forging die comprising a first forging surface and a second forging surface, and positioning the burner head intermediate the first forging surface and the second forging surface during the heating of the region of the forging surface. In one non-limiting embodiment, the burner head can be positioned a distance of 0.5 inches to 8 inches, a distance of 1 inch to 6 inches, or a distance of 1.5 inches to 3 inches, for example, from the region of the forging surface of the forging die prior to impinging the at least two flames onto the region of the forging surface. In various non-limiting embodiments, the burner head can be positioned, parallel, or substantially parallel, to the region of the forging surface of the forging die during flame impingement. In various other non-limiting embodiments, the burner head can comprise a surface having an area which corresponds to and/or is substantially the same as an area of the forging surface.
In one non-limiting embodiment, the method can comprise monitoring the temperature of at least a portion of a forging die and intermittently impinging, based on the monitoring, at least two flames, such as oxy-fuel flames, for example, onto a forging surface of the forging die to adjust the temperature of at least the portion of the forging surface and/or the forging die to at least a minimum desired temperature. In such non-limiting embodiments, thermocouples, thermopiles, fiber optic infra-red sensors, heat flux sensors, and/or other devices suitable for converting thermal energy into electrical energy (together referred to herein as “temperature sensors”) can be positioned within the forging die, around the perimeter of the forging die, on forging surfaces of the forging die, and/or within the flame ports of the burner head, for example, such that an operator of a forging die heating apparatus can receive feedback as to the temperature of the forging surfaces of the forging die during a forging die preheating process. In one non-limiting embodiment, the temperature sensors can be rated for sensing temperatures in the range of 800-3000° Fahrenheit, for example. Suitable temperature sensors such as thermocouples, for example, are readily commercially available and, therefore, are not discussed further herein.
One exemplary non-limiting embodiment of the positioning of the temperature sensors that may be used in certain embodiments according to the present disclosure is illustrated in
In one non-limiting embodiment, referring to
In one non-limiting embodiment, and referring to
In one non-limiting embodiment, referring to
Optional temperature sensors 770, labeled 1-3, can be positioned on and/or within the top portion 712 of the forging die and proximate to the forging surface 716 to measure the temperature of regions of the top portion 712. Of course, similar temperature sensors, or other types of temperature sensors, can be positioned on and/or within a bottom portion (not illustrated) or other portion of the forging die. The temperature sensors 770 can be the same as or similar to the temperature sensors 670 described above and, therefore, will not be described in detail with respect to
In one non-limiting embodiment, referring to
In another non-limiting embodiment, a proportional-integral-derivative (“PID”) controller (not illustrated), as is known to those of ordinary skill in the art, can be used in the closed loop on/off flame impingement system in lieu of the logic controller 804. The PID controller can be used to control the opening and/or closing of the solenoid valves 808 in a similar fashion as the logic controller 804. In various non-limiting embodiments, and, of course, depending on the material composition of the forging dies and/or the burner head 822, the temperature can be maintained between 700 and 2000 degrees Fahrenheit, when using an oxy-fuel, for example.
In one non-limiting embodiment, the oxidizing gas and the fuel can be fed into a flow regulator 814. The flow regulator 814 may include flow rate gauges 816 and pressure gauges 818 for monitoring the flow rate and pressure, respectively, of the oxidizing gas and the fuel through the flow regulator 814. The flow regulator 814 may also include the solenoid valves 808, which are configured to open and close based on pulses, or signals, received from the logic controller 804. If the solenoid valves 808 are open, or partially open, the oxidizing gas and the fuel can be fed through the flow regulator 814 and, if the solenoid valves 808 are closed, the oxidizing gas and the fuel will not be allowed to flow through the flow regulator 814. As such, the logic controller 804 can send pulses, or signals, to the solenoid valves 808 to open and/or close the solenoid valves 808 and intermittently permit the flow of the oxidizing gas and the fuel through the flow regulator 814. Of course, the flow rate of the oxidizing gas and the flow rate of the fuel can have any suitable ratio suitable for adequate combustion.
In one non-limiting embodiment, still referring to
As discussed above, the burner head 822 can be cooled using a liquid, vapor, and/or a gas, for example. In one non-limiting embodiment, water 826 from a facility can be fed into the burner head 822, run through the burner head 822 to cool the burner head 822 by absorbing heat from the metal portions of the burner head 822, and then flowed out of the burner head 822 to a water recycle or waste pit 828 or other suitable waste area. A temperature sensor 830 can be provided in the waste line between the burner head 822 and the water recycle or waste pit 828 to track the temperature of the waste water. The temperature of the waste water may, in some instances, indicate to an operator that the burner head 822 is overheating. In one non-limiting embodiment, the temperature of the waste water may normally be above the ambient temperature and/or within the range of 60 degrees Fahrenheit to 90 degrees Fahrenheit, for example, depending on the flow rate of the waste water. If the temperature of the waste water reaches about 110 degrees Fahrenheit, for example, this may indicate that the burner head 822 is overheating and should be shut down or that more cooling water should be provided to the burner head 822. In other non-limiting embodiments, if the temperature sensor 830 senses a temperature of the waste water at approximately 110 degrees Fahrenheit, for example, the burner head 822 may be automatically shut down or more cooling water may be automatically provided to the burner head 822. Those of skill in the art will recognize that the temperature sensor 830 can read thermal energy of the waste water and convert that thermal energy into electrical energy. The electrical energy can then be provided to the display 806. As referenced above, the display 806 may include the appropriate circuitry to interpret the electrical energy and provide a readout indicative of the temperature of the waste water.
In one non-limiting embodiment, referring to
In one non-limiting embodiment, the one or more IR thermometers 914 may need to be jacketed or shielded to protect heat sensitive areas, such as the electronics and the optics (i.e., lens), for example, of the one or more IR thermometers 914 from the high temperature air surrounding the burner head 922 and/or from the heat being radiated by the burner head 922 and/or the forging surface 916. In certain non-limiting embodiments, due to potential thermal degradation of especially the electronics and optics of the one or more IR thermometers 914 caused by exposure to hot gases flowing through the one or more apertures 920, a small blower 921, such as a 75 cubic feet per hour blower, for example, may be used to deflect the hot gases from the one or more IR thermometers 914. The blower 921 may be positioned such that it provides air flow in a direction along or substantially along the face 918, for example, as indicated by the arrows of
In one non-limiting embodiment, as discussed above, a forging die drift equipment safety-hard stop or spacer can be used to prevent, inhibit, or at least minimize a top portion of a forging die from drifting or being forced downwards into a portion of the forging die heating apparatus and crushing or damaging the portion of the forging die heating apparatus between the top portion and a bottom portion of the forging die during a power outage at a facility. The forging die drift hard-stop or spacer and the forging die heating apparatus can be attached to and/or operably engaged with an automation arm, such as a compressed air automation arm, for example, that can be controlled by an operator using a simple panel of switches, software switches, and/or any other suitable device. The “On” position of the switches can set the forging die in “preheat mode” by bringing the top and bottom portions of the forging die into a preheating, partially closed, or substantially closed position. The forging die heating apparatus and the forging die drift hard-stop or spacer can then be moved into a position at least partially intermediate the top and bottom portions of the forging die and flames in flame ports of a burner head can be ignited using a spark plug, a pilot igniter, a pilot lamp igniter, and/or any other suitable igniting device. The forging die heating apparatus can then be used to preheat the forging die, or regions thereof, and maintain the forging die, or regions thereof, at a predetermined required or desirable temperature or within a predetermined required or desirable temperature range. The “Off” position of the switches can shut off and/or extinguish the flames in the flame ports of the burner head (by eliminating a supply of an oxidizing gas and a supply of a fuel from being provided to the flame ports, for example) and retract the forging die heating apparatus from the position at least partially intermediate the top and bottom portions of the forging die using the automation arm into a position where the forging die heating apparatus is clear of the forging die. The forging die can then be set into the normal “forging” mode. As is apparent to those of ordinary skill in the art, the forging die heating apparatus can also be positioned and removed from a position intermediate the top and bottom portions of the forging die manually, or with other types of automation, for example.
In one non-limiting embodiment, referring to
In one non-limiting embodiment, the forging die drift hard-stop system 1018 may comprise a spacer 1026 attached to a first end of an arm 1028. A second end of the arm may be pivotably attached to a portion of the forging die apparatus 1000, such that the arm 1028 may pivot with respect to the forging die apparatus 1000 to allow movement of the spacer 1026 relative to the forging die apparatus 1000. A lever 1030 may be fixedly or pivotably attached to the arm 1028 at a location intermediate the first end and the second end of the arm 1028. The lever 1030 may comprise a gripping handle 1031 on a first end and an engagement member 1033 on a second end. The lever 1030 and/or the gripping handle 1031 may be used by an operator of the forging die apparatus 1000 to move the spacer 1026 from a first, disengaged position (illustrated in dashed lines) into a second, engaged position (illustrated in solid lines), and then, at an appropriate time, to move the spacer 1026 from the second, engaged position back into the first, disengaged position. When the spacer 1026 is in the first, disengaged position, the engagement portion 1033 of the lever 1030 can contact a plate, a bracket, or a solid portion 1032 of the forging die apparatus 1000 to hold the spacer 1026 in the first, disengaged position where the spacer 1026 will not prevent the top portion 1012 of the forging die 1010 from moving towards the bottom portion 1014 of the forging die 1010. In other various non-limiting embodiments, an actuator (not illustrated) can be operatively engaged with the arm 1028, the lever 1030, and/or the spacer 1026 to, upon activation, accomplish movement of the spacer 1026 between the first, disengaged position and the second, engaged position.
In one non-limiting embodiment, the solid portion 1032 may include an end 1036 configured to receive a portion of the spacer 1026, when the spacer 1026 is in the second, engaged position. Upon movement of the spacer 1026 into the second, engaged position, the spacer 1026 may be at least partially positioned intermediate the solid portion 1032 and a portion of the cross head 1025 to prevent, or at least inhibit, the top portion 1012 of the forging die 1010 from drifting and/or moving toward the bottom portion 1014 of the forging die 1010 at an inappropriate time. The spacer 1026 may be comprised of a material sufficient to withstand the weight and/or force of the bolster 1024, the cross head 1025, and the top portion 1012 of the forging die 1010. In one non-limiting embodiment, although not illustrated, a forging die drift hard-stop system may be provided on more than one side of the forging die apparatus 1000 to maintain a balance of the weight of the cross head 1025, the bolster 1024, and/or the top portion 1012 of the forging die 1010. In yet another non-limiting embodiment, a winch, such as an electrical winch (not illustrated), for example, optionally mounted to the forging die apparatus 1000, may be configured to control the movement of the spacer 1026, the arm 1028, and/or the lever 1030, for example. The electrical winch may comprise a wire or a cable, for example, that is extendible from the winch and retractable toward the winch. The electrical winch may also comprise limit switches configured to control the range of motion of the spacer 1026, the arm 1028, and/or the lever 1030, for example. In one embodiment, the electrical winch may be configured to extend or uncoil the wire or cable to move the spacer 1026 from the first, disengaged position into the second, engaged position. The movement of the spacer 1026 may occur owing to gravitational forces acting upon the spacer 1026. The electrical winch may also be configured to move the spacer 1026 from the second, engaged position into the first, disengaged position by retracting or coiling the wire or cable. In one embodiment, the wire or cable may be attached to the electrical winch at a first end and attached to the arm 1028 at a second end. In such an embodiment, the lever 1030 can be eliminated. In an embodiment where the forging die drift hard-stop system 1018 is positioned on both sides of the forging die apparatus 1000, the spacer 1026, the arm 1028, and/or the lever 1030 of each forging die drift hard-stop system 1018 may be moved simultaneously from the first, disengaged position into the second, engaged position, or vice versa, using a single pair of electrical switches, thereby making the forging die drift hard-stop system 1018 easy to operate.
In one non-limiting embodiment, a method of preheating an open-faced forging die can comprise positioning a burner head comprising at least two flame ports in a location at least partially intermediate a first forging surface of the forging die and a second forging surface of the forging die. In such an embodiment, the burner head can be slid, swung, pivoted, and/or moved into and out of the position at least partially intermediate the first forging surface and the second forging surface, for example. Such sliding, swinging, pivoting, and/or movement can be manual or automated. In one non-limiting embodiment, the forging die heating apparatus can be attached in a transverse, perpendicular, or substantially perpendicular manner to a vertically, or substantially vertically extending support member, such as the wall 384 of
In one non-limiting embodiment, an orientation of a burner head can at least partially conform to at least one of an orientation of a first forging surface of a forging die and an orientation of a second forging surface of the forging die. A method for heating a forging die can comprise supplying a fuel to at least two flame ports, combusting the fuel to produce a flame at the least two flame ports, and impinging at least two of the flames onto at least one of the first forging surface and the second forging surface. The method can also comprise positioning a spacer between the first forging surface and the second forging surface to prevent, inhibit, or at least minimize the first forging surface from moving toward the second forging surface when the burner head is positioned at least partially intermediate the first forging surface and the second forging surface. As discussed above, the fuel can comprise an oxy-fuel. The method can further comprise impinging at least two oxy-fuel flames onto at least one of the first forging surface and the second forging surface through the at least two flame ports to uniformly, or substantially uniformly, preheat at least one of the first forging surface and the second forging surface.
In one non-limiting embodiment, referring to
Further to the above, in one non-limiting embodiment, the arm 1104 may be moved between a stored position (not illustrated), where a burner head 1112 of the burner assembly 1100 may be positioned adjacent to or proximate to a portion of the support member 1102, and a deployed position, where the burner head 1112 may be positioned most distal from the support member 1102. As referenced above, the arm 1104 may be moved between the stored position and the deployed position by pivoting the arm 1104 about the pivot point 1110. In one non-limiting embodiment, the burner head 1112 may be attached to or formed with the arm 1104 proximate to an end of the arm 1104 most distal from the pivot point 1110. In other non-limiting embodiments, the burner head 1112 may be attached to or formed with other suitable portions of the arm 1104. Walls of the arm 1104 may define a channel therethrough in a longitudinal direction. The channel may be used to supply a combustible fuel, such as natural gas, for example, to the burner head 1112. The combustible fuel may be supplied to the burner head 1112 at about 30 psi, for example. In one non-limiting embodiment, a tube (not illustrated) may be positioned within the channel such that the combustible fuel may flow from a fuel supply, through the tube, and to the burner head 1112.
In one non-limiting embodiment, still referring to
In one non-limiting embodiment, the burner head 1112 may comprise a housing portion 1116 and a burner head portion 1118. The housing portion 1116 may comprise a manifold 1120 configured to receive the combustible fuel from the channel, or the tube within the channel, of the arm 1104. The manifold 1120 may be in fluid communication with a plurality of conduits 1122 used to flow the combustible fuel to one or more assemblies 1124. In one non-limiting embodiment, the manifold 1120 may be in fluid communication with six conduits 1122 used to flow the combustible fuel to six assemblies 1124, for example. The assemblies 1124 may each comprise an orifice configured to allow a predetermined amount of the combustible fuel to flow therethrough. The orifices may have a diameter in the range of about 30 mils to about 100 mils, for example. The orifices may regulate and/or restrict the flow of the combustible fuel through the assemblies 1124 to provide a suitable amount of the combustible fuel to the burner head portion 1118. In one non-limiting embodiment, the assemblies 1124 may also comprise an air aspirator configured to allow ambient air to bleed or flow into the assemblies 1124. The air aspirator may at least partially surround the assemblies 1124, for example, such that the ambient air may flow or bleed into the assemblies 1124 from any suitable direction. As a result of the air aspirator, the combustible fuel may be mixed with the ambient air (i.e., oxidizing gas) within a plurality of tubes 1126. The plurality of tubes 1126 may be in fluid communication with at least one burner nozzle 1128 positioned on the burner head portion 1118. In one non-limiting embodiment, the plurality of tubes 1126 may be in fluid communication with three or more burner nozzles 1128 within the burner head portion 1118, for example. The housing portion 1116 may comprise a shell 1130 that may at least partially surround the conduits 1122, the assemblies 1124, and/or the tubes 1126 to protect the conduits 1122, the assemblies 1124, and/or the tubes 1126 from being smashed or damaged during use of or storage of the burner head 1112 and/or to provide a heat shield for the conduits 1122, the assemblies 1124, and/or the tubes 1126, for example.
Further to the above, still referring to
In operation, the burner assembly 1100 may be positioned or mounted proximate to a forging die. The arm 1104 may be moved or pivoted from the stored position into the deployed position. The actuator 1114 may then be activated to move the burner head 1112 from a position where the central longitudinal axis of the burner head 1112 is generally parallel with the central longitudinal axis of the arm 1104 to a position where the burner head 1112 is at about a 90 degree angle with respect to the central longitudinal axis of the arm 1104. As the burner head 1112 is moved into the about 90 degree position, it may also be moved into a position at least partially intermediate a top forging surface and a bottom forging surface of a forging die, for example. In one non-limiting embodiment, the burner nozzles 1128 on the first side 1132 of the burner head portion 1118 may be positioned between four and eight inches away from the top forging surface and, likewise, the burner nozzles 1128 on the second side 1134 of the burner head portion 1118 may be positioned between about four and about eight inches away from the bottom forging surface. In other non-limiting embodiments, the burner nozzles 1128 on the first side 1132 and the second side 1134 may each be positioned about six inches away from the top and bottom forging surfaces of the forging die, for example.
In one non-limiting embodiment, one or more of the burner nozzles 1128 on the first side 1132 and/or the second side 1134 may extend a different distance from the first side 1132 and/or the second side 1134 than other burner nozzles 1128 positioned on the first side 1132 and/or the second side 1134 in order to heat a forging surface of a vee die or another forging die, for example. In other non-limiting embodiments, the burner nozzles 1128 may also be situated a various angles relative to the first side 1132 and/or the second side 1134, again such that the burner head 1112 may be configured to heat a vee die or another forging die, for example. In one exemplary non-limiting embodiment, three rows of three burner nozzles 1128 per row may be provided on the first side 1132 and the second side 1134 of the burner head portion 1118. A first row of the burner nozzles 1128 and a third row of the burner nozzles 1128 may extend a first distance from the first side 1132 and/or the second side 1134 and a second row of the burner nozzles 1128 may extend a second distance from the first side 1132 and/or the second side 1134. The first distance may be larger than or smaller than the second distance such that the burner head 1112 may be configured for use with forging die surfaces having various configurations, orientations and/or shapes. In other non-limiting embodiments, the burner nozzles 1128 within each row may extend a different distance from the first side 1132 and/or the second side 1134 and/or may extend at different angles relative to the first side 1132 and/or the second side 1134, for example. Those of skill in the art, upon consideration of the present disclosure, will recognize that the various burner nozzles 1128 may have any suitable configuration or orientation for appropriately heating variously shaped forging surfaces or forging dies.
The burner assembly 1100 may be used to preheat or heat a forging die and/or one or more forging surfaces of the forging die from room temperature to about 1000 degrees Fahrenheit in approximately 30 to 45 minutes, for example. Of course, other heating rates may also be achieved by varying the amount of the combustible fuel or the air provided to the burner head 1112 by adjusting the sizes of the orifices and/or the air aspirators of the assemblies 1124, by varying the number of burner nozzles 1128 provided on the burner head 1112, and/or by varying the configuration and/or orientation of the burner nozzles 1128 on the first and second sides 1132 and 1134 of the burner head 1112, for example. While the burner assembly 1100 has been described as using a combustible fuel, such as natural gas, those of skill in the art will recognize that other suitable combustible fuels may be used with the burner assembly 1100.
It will be recognized by those of skill in the art that features or components of particular non-limiting embodiments described herein can be used in conjunction with other non-limiting embodiments described herein and/or with other non-limiting embodiments within the scope of the claims.
Although the foregoing description has necessarily presented only a limited number of embodiments, those of ordinary skill in the relevant art will appreciate that various changes in the apparatuses and methods and other details of the examples that have been described and illustrated herein may be made by those skilled in the art, and all such modifications will remain within the principle and scope of the present disclosure as expressed herein and in the appended claims. For example, although the present disclosure has necessarily only presented a limited number of non-limiting embodiments of forging die heating apparatuses, and also has necessarily only discussed a limited number of non-limiting forging die heating methods, it will be understood that the present disclosure and associated claims are not so limited. Those having ordinary skill will readily identify additional forging die heating apparatuses and methods and may design and build and use additional forging die heating apparatuses and methods along the lines and within the spirit of the necessarily limited number of embodiments discussed herein. It is understood, therefore, that the present invention is not limited to the particular embodiments or methods disclosed or incorporated herein, but is intended to cover modifications that are within the principle and scope of the invention, as defined by the claims. It will also be appreciated by those skilled in the art that changes could be made to the non-limiting embodiments and methods discussed herein without departing from the broad inventive concept thereof.
