Development New Method of Deformation Ingots Based on Forging of Profiled Workpieces

Abstract

Quantity of massive parts produced from an ingot is increasing today. It is caused by increasing of a massive equipment powerful. However, the quality of produced forging parts does not corresponds to customer`s requirements.Poor quality of the produced forging parts is caused by low quality of forging ingots.Defects of ultrasonic test after forging of the massive forging parts equal to 10%. The defects after ultrasonic test are caused by upsetting operation of the ingots with no equal internal structure. As a result, internal structure is processed unevenly and insufficiently. Increasing of the ingot internal defects occurs during upsetting operation of billets by flat deformationtools.The purpose of this work is establishing the rational geometry of billets with conical faces which guarantee the welding of the axial defects during upsetting operation.Rising diameter of conical face provide decreasing of defect welding degree. The toll conical faces rise the degree of thewelding defects. It was established that decreasing of the diameter and rising of the height the conical faces provide to reduction of convexity of the workpiece. In the initial step of the upsetting operation the “double convexity” is occurred. The convexity is growing at the diameter decrease of the conical faces. The “double convexity” levels out and the external surface of the workpiece obtains the nearly cylindrical shape in the finish upsetting. The relative height and diameter of the conical faceshave to be 0.4...0.6 and 0.5...0.7 respectively concerning the welding defects and equable distribution of the deformations at the upsetting. Obtained data of the upsetting in the manufactured conditions verified the established technological recommendations ofthe workpiece shape and dimensions obtained by theoretical modeling.