Manufacturing of ultra-large plate forgings by unfolding and flattening of thick cylinders
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Manufacturing of ultra-large plate forgings by unfolding and flattening of thick cylinders DENG Zheng-hua(邓正华)1, 2, WEN Tong(温彤)1, YOU Jian-hao(游建豪)1, DU Kang-kang(杜康康)1, SUN Lei(孙嫘)2 1. College of Materials Science and Engineering, Chongqing University, Chongqing 400044, China; 2. Erzhong (Deyang) Heavy Equipment Co. Ltd., Deyang 618000, China © Central South University Press and Springer-Verlag GmbH Germany, part of Springer Nature 2020 Abstract: Ultra-large plate forgings are foundation of heavy machinery, but many parts of the type cannot be made by conventional technologies due to the characters of extreme manufacturing in terms of size and quality requirements. This paper introduced a systematically method called cylinder unfolding method (CUM) for producing large plate forgings, by using a serial of operations including “splitting”, “unfolding”, and “flattening” of a thick cylinder obtained from saddle forging. The technological route of CUM was presented in detail with an example of plate forging with the horizontal sizes of 6100 mm and thickness of 300 mm. The deformation features of saddle forging for fabricating transitional cylinders were analyzed, and then the subsequent handling steps including splitting, unfolding and flattening of the cylinder, as well as the auxiliary processing, were addressed. The practice proved that CUM can provide an efficient way for manufacturing ultra-large plate forgings and meet the strict requirements in geometry and mechanical performance, without highly increasing the investments of forming equipment and tooling. Key words: extreme manufacturing; ultra-large plate forging; cylinder unfolding method; metal forming Cite this article as: DENG Zheng-hua, WEN Tong, YOU Jian-hao, DU Kang-kang, SUN Lei. Manufacturing of ultra-large plate forgings by unfolding and flattening of thick cylinders [J]. Journal of Central South University, 2020, 27(8): 2227−2238. DOI: https://doi.org/10.1007/s11771-020-4444-5.
1 Introduction Plates are fundamental structural components with the geometric feature where the thickness is far less than length and width. Large, thick plates are widely used in heavy industrial fields such as metallurgy, machinery, electric power, petroleum, chemical, shipbuilding, aviation [1, 2]. There is no specific definition of the range of “large”: it depends on the relative size compared to the common production capacity of the equipment in industrial fields. Generally, if the plane dimensions
of a plate exceed 5000 mm and the thickness is larger than 200 mm, it can be considered to be a large one. Besides the geometric requirements in shape and dimension, the organization structure and mechanical properties of large forgings must be taken into full consideration to meet the rigorous demands in service. So far, manufacturing technologies of plates mainly include rolling and free forging [3]. Rolling is suitable for mass production, and the surface quality is good. However, the equipment investments are huge, and the maximum sizes of the rolled plates are limited
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