1. Field of the Invention
The invention relates to a method for expanding a ring, and more particularly to a method for expanding a rectangular section ring to form a non-rectangular section ring.
2. Description of the Related Art
The rectangular section ring (referring to a ring having a rectangular cross section) or the non-rectangular section ring (referring to a ring having a non-rectangular section) of the high temperature alloy generally has poor dimensional accuracy after being rolled by a ring rolling machine due to the limitations of the rolling process and the rolling device. Only when the ring has an ideal shape and the device presents relatively excellent performance, the dimensional accuracy is approximately between 3% and 5% of the corresponding dimension. Besides, defects including warp, deformation, and even cracking easily occur on the ring as a result of a relatively large stress in subsequent processing operations.
Conventional methods for expanding of a ring are based on the flexible contact between the liquid and an inner circumferential surface of the ring. The methods are only applicable for materials having small deformation resistance and mainly operate to reinforce the ring. However, the methods are neither applicable for materials having large deformation resistance, such as a high temperature alloy, nor applicable for expanding a rectangular section ring into a non-rectangular section ring. Furthermore, the methods are unable to solve the poor dimensional accuracy existing in the prior art.
In view of the above-described problems, it is one objective of the invention to provide a method for expanding a rectangular section ring to form a non-rectangular section ring. The method utilizes an expanding block to deform a rectangular section ring of a high temperature alloy into a non-rectangular section ring. One large deformation and three continuous small deformations are conducted to expand the high temperature rectangular section ring, thereby obtaining the non-rectangular section ring having high dimensional accuracy.
To achieve the above objective, in accordance with one embodiment of the invention, there is provided a method for expanding a rectangular section ring to form a non-rectangular section ring, the method comprises:
In a class of this embodiment, the high temperature alloy is a GH4169 alloy.
In a class of this embodiment, the axial tension F exerted on the mandrel slider by the expanding machine is determined by the following equation: F=ξ×σ0.2×S, in which, ξ represents an expanding coefficient of the expanding machine and is valued between 1.26 and 1.52; σ0.2 represents a yield strength (megapascal) of the high temperature alloy at the expanding temperature, and σ0.2 of the GH4169 alloy is valued between 380 and 430 megapascal; and S represents a longitudinal section area (mm2) of the rectangular section ring or the profiled ring billet.
In a class of this embodiment, the expanding size of the non-rectangular section ring at a hot state is calculated as follows: D=D0(1+βt)+d, in which, D represents an inner diameter (mm) of the non-rectangular section ring at the hot state; D0 represents an inner diameter (mm) of a final product of the non-rectangular section ring at a cold state; βt represents a temperature compensation coefficient (%) of the alloy material at the expanding temperature, and βt of the GH4169 alloy is between 1.5% and 1.75%; and d represents a resilience value (mm) of the inner diameter of the non-rectangular section ring after the expanding, and d of the GH4169 alloy is between 3 and 5 mm.
In a class of this embodiment, the non-rectangular section ring has an inner diameter of between Φ400 mm and Φ4500 mm, a wall thickness of between 10 and 200 mm, and a height of between 40 and 750 mm.
Advantages according to embodiments of the invention are summarized as follows:
The non-rectangular section ring is directly formed by rigid contact between the expanding block of the expanding machine and the rectangular section ring of the high temperature alloy. The method of the invention is capable of expanding high temperature alloy material that has relatively large deformation resistance and is difficult for deformation, thereby obtaining the demanded expanding dimension and improving the dimensional accuracy.
By heating the rectangular section ring to a high temperature, the method adopts one large deformation to deform the rectangular section ring to yield the profiled ring billet and adopts another three small deformations to deform the profiled ring billet into the non-rectangular section ring. Technological parameters including the expanding temperature, the expanding time, and the retention time are reasonably selected, so that neither obvious change in the tissue of the ring nor crack occurs, and the resilience value of the ring or the profiled ring billet is relatively small after each expanding process. During the expanding process, the profiled ring billet is rotated for 45° for three times in the same direction, which eliminates the traces formed on the inner circumferential surface of the profiled ring billet resulting from gaps between adjacent expanding blocks during the radial dispersion of the expanding blocks, thereby being beneficial for the expanding process and obtaining the non-rectangular section ring after the expanding having relatively high dimensional accuracy. During the whole expanding process, the expanding block is capable of real time measuring the change of the inner diameter of the profiled ring billet and the resilience value of the inner diameter after each expanding process and sending the measured data to a displayer of the expanding machine in time, so that the expanding dimension of the non-rectangular section ring can be precisely controlled during the expanding process. In a word, the non-rectangular section ring produced by the hot expansion forming method of the invention has relatively high dimensional accuracy.
During the expanding process, the axial tension F acted on the mandrel slice of the expanding machine is determined by the expanding coefficient (ξ), the yield strength (σ0.2) of the material at the expanding temperature, and the cross section area (S) of the rectangular section ring or the profiled ring billet. Thus, the axial tension F is determined according to different expanding machines, different materials, and different ring or profiled ring billet having different dimensions, thereby resulting in a uniform and reasonable stress of the ring, ensuring a smooth expanding process, and preventing the crack caused by an excessive force or expanding failure caused by a too small force.
The inner diameter (D) of the non-rectangular section ring at the hot state is calculated by the inner diameter (D0) of the final product of the non-rectangular section ring at the cold state, the temperature compensation coefficient (βt) of the alloy material at the expanding temperature, and the resilience value (d) of the inner diameter of the non-rectangular section ring after the expanding, so that the dimension of the non-rectangular section ring at the hot state can be precisely controlled during the expanding process and the dimension of the non-rectangular section ring after the expanding at the cold state having the high accuracy is the final product dimension.
Taken non-rectangular section ring of the high temperature alloy GH4169 as an example, the dimension of the non-rectangular section ring after expanding at the cold state is the final product dimension, a dimensional accuracy reaches between 1% and 2% of the corresponding dimension. It is known from the detection that the inner tissue of non-rectangular section ring of such alloy has no obvious change, deformation, or crack.
The invention is described hereinbelow with reference to the accompanying drawings, in which:
For further illustrating the invention, experiments detailing a method for expanding a rectangular section ring to form a non-rectangular section ring are described below. It should be noted that the following examples are intended to describe and not to limit the invention.
Take the Chinese material grade GH4169 of a high temperature alloy as an example. The GH4169 alloy comprises: less than or equal to 0.08 wt. % of carbon, between 17.0 wt. % and 21.0 wt. % of Cr, between 50.0 wt. % and 55.0 wt. % of Ni, less than or equal to 1.0 wt. % of Co, between 2.80 wt. % and 3.30 wt. % of Mo, between 0.30 wt. % and 0.70 wt. % of Al, between 0.75 wt. % and 1.15 wt. % of Ti, between 4.75 wt. % and 5.50 wt. % of Nb, less than or equal to 0.006 wt. % of B, less than or equal to 0.01 wt. % of Mg, less than or equal to 0.35 wt. % of Mn, less than or equal to 0.35 wt. % of Si, less than or equal to 0.015 wt. % of P, less than or equal to 0.015 wt. % of S, less than or equal to 0.30 wt. % of Cu, less than or equal to 0.01 wt. % of Ca, less than or equal to 0.0005 wt. % of Pb, less than or equal to 0.0003 wt. % of Se, and Fe.
The hot expansion forming method is conducted on an expanding machine. As shown in
A hot expansion forming process for shaping the GH4169 alloy from a rectangular section ring to a profiled piece is as follows:
Step 1: Mounting the Rectangular Section Ring on the Expanding Machine
As shown in
Step 2: Performing a First Expanding
As shown in
The expanding time refers the duration from the start of the expanding of the rectangular section ring to the end of the expanding process. The retention time refers the duration from when the deformation of the rectangular section ring 10 reaches the expanding deformation and no more deformation occurs until the expanding process is finished.
Step 3: Performing a First Rotation
As shown in
Step 4: Performing a Second Expanding
The expanding process of step 1) is repeated to perform a second expanding process on the profiled ring billet 15 by the expanding block 3. During the second expanding process, the axial tension F is exerted on the mandrel slider 1 by the hydraulic cylinder of the expanding machine. The expanding temperature of the profiled ring billet 15 is controlled between 960 and 980° C., the expanding time is controlled between 20 and 30 seconds, the retention time is controlled between 10 and 15 seconds, and the expanding deformation is controlled between 1.8% and 2%.
Step 5: Performing a Second Rotation
Step 3) is repeated to drive the profiled ring billet 15 to rotate for another 45° in the same direction of the first rotation, whereby finishing the second rotation of the profiled ring billet 15.
Step 6: Performing a Third Expanding
The expanding process of step 1) is repeated to perform the third expanding process on the profiled ring billet 15 by the expanding block 3. During the third expanding process, the axial tension F is exerted on the mandrel slider 1 by the hydraulic cylinder of the expanding machine. The expanding temperature of the profiled ring billet 15 is controlled between 930° C. and 950° C., the expanding time is controlled between 20 and 30 seconds, the retention time is controlled between 10 and 15 seconds, and the expanding deformation is controlled between 1.3% and 1.5%.
Step 7: Performing a Third Rotation
Step 3) is repeated to drive the profiled ring billet 15 to rotate for another 45° in the same direction of the second rotation, whereby finishing the third rotation of the profiled ring billet 15.
Step 8: Performing a Fourth Expanding
The expanding process of step 1) is repeated to perform the fourth expanding process on the profiled ring billet 15 by the expanding block 3 to yield the final non-rectangular section ring 20. During the fourth expanding process, the axial tension F is exerted on the mandrel slider 1 by the hydraulic cylinder of the expanding machine. The expanding temperature of the profiled ring billet 15 is controlled between 900 and 920° C., the expanding time is controlled between 30 and 40 seconds, the retention time is controlled between 25 and 28 seconds, and the expanding deformation of the profiled ring billet 15 is controlled between 1.2% and 1.4%.
After the fourth expanding processes, the mandrel slider 1 moves upward, the radial slider 2 aggregates to separate the expanding block 3 from the non-rectangular section ring 20, and the non-rectangular section ring 20 is collected by the manipulator.
During the expanding process of the rectangular section ring 10 or the profiled ring billet 15, the axial tension F is calculated as follows:
F=ξ×σ
0.2
×S
in which, ξ represents an expanding coefficient of the expanding machine and is valued between 1.26 and 1.52; σ0.2 represents a yield strength (megapascal) of the high temperature alloy at the expanding temperature and is valued between 380 and 430 megapascal; and S represents a longitudinal section area (mm2) of the rectangular section ring 10 or the profiled ring billet 15.
The expanding deformation of the rectangular section ring 10 is calculated as follows:
Expanding deformation={[Pitch diameter of the rectangular section ring 10 (or the profiled ring billet 15) after expanding−Pitch diameter of the rectangular section ring 10 (or the profiled ring billet 15) before expanding]/Pitch diameter of the rectangular section ring 10 (or the profiled ring billet 15) before expanding}×100%.
Pitch diameter of the rectangular section ring 10 (or the profiled ring billet 15)=(Inner diameter of the rectangular section ring 10 (or the profiled ring billet 15)+Outer diameter of the rectangular section ring 10 (or the profiled ring billet 15))÷2.
To ensure a required size of the final product after the expanding deformation of the rectangular section ring 10 into the non-rectangular section ring 20, the expanding size of the non-rectangular section ring 20 at the hot state is calculated as follows:
D=D
0(1+βt)+d
in which, D represents the inner diameter (mm) of the non-rectangular section ring 20 at the hot state; D0 represents the inner diameter (mm) of the final product of the non-rectangular section ring 20 at a cold state; βt represents a temperature compensation coefficient (%) of the alloy material at the expanding temperature, different materials has different temperature compensation coefficient at different temperature, and herein the temperature compensation coefficient is valued between 1.5% and 1.75%; and d represents a resilience value (mm) of the inner diameter of the non-rectangular section ring 20 after expanding, and the resilience value herein is valued between 3 and 5 mm.
The above dimensions in the calculation are all dimensions of the maximum deformation, and herein are dimensions of large end face, or the bottom end face, of the rectangular section ring 10 or the profiled ring billet 15.
The non-rectangular section ring of the high temperature alloy formed by using the above hot expansion forming method has an inner diameter of between Φ400 mm and Φ4500 mm, a wall thickness of between 10 and 200 mm, and a height of between 40 and 750 mm.
The non-rectangular section ring is directly formed through the rigid contact between the expanding block of the expanding machine and the rectangular section ring of the high temperature alloy. The method of the invention is capable of expanding high temperature alloy material that has relatively large deformation resistance and is difficult for deformation, thereby obtaining the demanded expanding dimension and improving the dimensional accuracy. It is known from the detection that the dimension of the alloy non-rectangular section ring at the cold state after the expansion forming process, that is, the final product dimension, has a dimensional accuracy reaching between 1% and 2% of the corresponding dimension, and that the inner tissue of non-rectangular section ring of such alloy has no obvious change, deformation, or crack. This method is applicable for producing the non-rectangular section ring of the high temperature alloy rotator parts such as cylindrical casing in the field of aerospace.
Unless otherwise indicated, the numerical ranges involved in the invention include the end values. While particular embodiments of the invention have been shown and described, it will be obvious to those skilled in the art that changes and modifications may be made without departing from the invention in its broader aspects, and therefore, the aim in the appended claims is to cover all such changes and modifications as fall within the true spirit and scope of the invention.
Number | Date | Country | Kind |
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201110377020.7 | Nov 2011 | CN | national |
This application is a continuation-in-part of International Patent Application No. PCT/CN2012/084952 with an international filing date of Nov. 21, 2012, designating the United States, now pending, and further claims priority benefits to Chinese Patent Application No. 201110377020.7 filed Nov. 24, 2011. The contents of all of the aforementioned applications, including any intervening amendments thereto, are incorporated herein by reference. Inquiries from the public to applicants or assignees concerning this document or the related applications should be directed to: Matthias Scholl P.C., Attn.: Dr. Matthias Scholl Esq., 14781 Memorial Drive, Suite 1319, Houston, Tex. 77079.
Number | Date | Country | |
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Parent | PCT/CN2012/084952 | Nov 2012 | US |
Child | 14285663 | US |