Forging锻造教学讲解课件

ForgingprocessesForgingprocessesForgingprocessesForgingproForgingProcessesHistoryofForging？Forgingisoneoftheoldestknownmetalworkingprocesses.Traditionally,forgingwasperformedbya

smith

usinghammerand

anvil(铁砧),thoughintroducingwaterpowertotheproductionandworkingofironinthe12thcenturydrovethehammerandanvilintoobsolescence(过时，淘汰).Video-hammerandanvilForgingProcessesHistoryofForgingProcessesHistoryofUnit4ForgingProcesses

WhatisForging？Itisanimportanthot-formingprocess.Itisusedinproducingcomponentsofallshapesandsizes,fromquitesmallitemstolargeunitsweighingseveraltons.锻造是一种重要的热成型工艺。用于生产各种形状和尺寸的零件，有的极小有的重达几吨。Itistheprocessbywhichmetalisheatedandisshapedbyplasticdeformationbysuitablyapplyingcompressiveforce.在此过程中金属被加热，通过适当应用压力产生塑性变形使金属成型。(video-largepartsforging)Unit4ForgingProcessesWhUnit4ForgingProcessesWh

Handforgingtoolscomprisevariouslyshaped

hammers.手工锻造工具包括各种不同形状的锤子。①Forthesemimechanizedforgingofsmalltomedium-sizedcomponents,forginghammerspoweredbyvariousmeansareemployed.对小到中等尺寸零件的半机械化锻造而言，采用锻锤，锻锤的驱动动力有多种方式。video-swordThefeaturecommontoallofthemisthat,likethehandforginghammer,theyutilizetheenergyofafallingweighttodevelopthepressureneededforshapingthemetal.无论采用什么样的驱动力，它们共同的特点就是(和手工锻锤一样)，都是利用落重能量来产生金属成型所需的压力。ForgingtoolsHandforgingtoolscomprisevHandforgingtoolscomprisev②Largercomponentsareforgedbymeansofforgingpressesoperatedbysteamorcompressedairorbyhydraulicorelectricpower.锻造大零件则要用到蒸汽、压缩空气、液力或电力驱动的锻压机。Largelyautomaticforgingmachinesareusedforthequantityproductionofengineeringparts.大型的自动化锻机用于工程零件的批量生产。Forgingtools②Largercomponentsareforged②LargercomponentsareforgedClassificationofforgingTherearemanydifferentkindsofforgingprocessesavailable,howevertheycanbegroupedintothreemainclasses:Drawnout:lengthincreases,cross-section

decreasesUpset:lengthdecreases,cross-sectionincreasesSqueezedinclosedcompressiondies:producesmultidirectionalflowDrawnout拔长cross-section横截面Upset镦粗Squeezed挤压,塞进

compressiondies压模closedcompressiondies封闭压模Video-拔长ClassificationofforgingVideoClassificationofforgingVideoDropForging落锻，落锤锻造Open-DieForging/HandForging开模段，手工锻，自由锻Closed-DieForging/Impression-DieForging/PrecisionForging闭模锻，模锻，精锻PressForgings

压力锻造UpsetForgings顶锻，镦锻RollForgings滚锻,辊锻Swaging（型锻,模锻,挤锻）NetShape/Near-NetShapeForgings精锻,纯型锻CommonForgingProcessesDropForging落锻，落锤锻造CommonForDropForging落锻，落锤锻造CommonForDropforgingisaforgingprocesswhereahammerisraisedandthen"dropped"ontotheworkpiecetodeformitaccordingtotheshapeofthedie.落锻过程即锻锤抬起再“落下”，落至工件使之变形。Therearetwotypesofdropforging:open-diedropforgingandclosed-diedropforging.有两种落锻：开模落锻和闭模落锻Asthenamesimply,thedifferenceisintheshapeofthedie,withtheformernotfullyenclosingtheworkpiece,whilethelatterdoes.顾名思义，两者之间区别在于模具的形状。开模锻没有完全封闭式包围工件，闭模锻却有。DropForging落锻，落锤锻造DropforgingisaforgingprocDropforgingisaforgingprocOpen-dieforgingisalsoknownas

smithforging.开模锻（自由锻）又称为铁匠的锻造Inopen-dieforging,ahammerstrikesanddeformstheworkpiece,whichisplacedonastationaryanvil.在开模锻中，工件放置在固定的铁砧上，由铁锤击打工件使之变形，Open-dieforginggetsitsnamefromthefactthatthedies(thesurfacesthatareincontactwiththeworkpiece)donotenclosetheworkpiece,allowingittoflowexceptwherecontactedbythedies.开模锻得名是因为模具没有封闭工件，使得工件可以自由流动（与模具接触的地方除外）1.open-dieforging开模段，手工锻，自由锻Open-dieforgingisalsoknownOpen-dieforgingisalsoknownTherefore,theoperator,needstoorientandpositiontheworkpiecetogetthedesiredshape.

因此操作者需要对工件进行定位和放置动作，才能获得需要的形状。1.open-dieforging开模段，手工锻，自由锻Therefore,theoperator,needsTherefore,theoperator,needsThediesareusuallyflatinshape,butsomehaveaspeciallyshapedsurfaceforspecializedoperations.Forexample,adiemayhavearound,concave,orconvexsurfaceorbeatooltoformholesorbeacut-offtool.自由锻的模具通常是平面，但在特殊操作中也会用到特殊形状表面。例如圆形表面，凹面，凸面，或是制孔工具，切断工具。1.open-dieforging开模段，手工锻，自由锻ThediesareusuallyflatinsThediesareusuallyflatinsOpen-dieforgingscanbeworkedintoshapeswhichincludediscs,hubs,blocks,shafts(includingstepshaftsorwithflanges),sleeves,cylinders,flats,hexes,rounds,plate,andsomecustomshapes.自由锻件可以被加工为各种形状，包括阀盘，衬套，块，轴(包括阶梯轴或带法兰盘的轴)，套筒，圆柱体，平板，六角形，圆形物，盘类，及一些自定义形状。1.open-dieforging开模段，手工锻，自由锻Video-球体Open-dieforgingscanbeworkeOpen-dieforgingscanbeworke

Open-dieforginglendsitselfto

shortrunsandisappropriateforartsmithingandcustomwork.手工锻适用于小批量生产，艺术锻造，及定制工作。Insomecases,open-dieforgingmaybeemployedtorough-shapeingots

topreparethemforsubsequentoperations.在一些情况下，自由锻被用于为机械加工等后续操作准备粗略成型的坯料。lenditselfto适宜于shortrun小批量Ingot锭，铸块1.open-dieforging开模段，手工锻，自由锻

Open-dieforginglendsitself

Open-dieforginglendsitselfItisverywidelyusedformassproduction

inindustry,inwhichthemetalisshapedbypressingbetweenapairofforgingdies.闭模锻广泛用于工业大批量生产，金属在一对锻模之间挤压成型。

Makeup：Theupperdieisusuallyattachedtotheram（撞头）ofaforgingpressoraforginghammer,whilethelowerdieisstationary.Togethertheyformacloseddie.Themetalisplacedinthelowerdie.组成：顶模通常附着在锻压机的撞头或锻锤上，底模则固定不动。金属就放置在底模上。2.closed-dieforging/Impression-dieforgingItisverywidelyusedformasItisverywidelyusedformasThehammeristhendroppedontheworkpiece,causingthemetaltoflowandfillthediecavities.锻锤落至工件，使得金属流动并填充模具模膛。Thehammerisgenerallyincontactwiththeworkpieceonthescaleofmilliseconds.Dependingonthesizeandcomplexityofthepart,thehammermaybedroppedmultipletimesinquicksuccession.通常锻锤和工件接触的速度以毫秒计。根据零件的尺寸和复杂性，锻锤快速连续地多次落锤。2.closed-dieforging/Impression-dieforgingThehammeristhendroppedonThehammeristhendroppedonExcessmetalissqueezedoutofthediecavities,formingwhatisreferredtoas"flash".多余的金属从模具模膛中挤出，形成所谓的“飞边”。Theflashcoolsmorerapidlythantherestofthematerial;thiscoolmetalisstrongerthanthemetalinthedie,soithelpspreventmoreflashfromforming.飞边的冷却速度比其余速度快。冷却后的飞边比模具内的金属强度大，从而防止形成更多的飞边。Thisalsoforcesthemetaltocompletelyfillthediecavity.Afterforging,theflashisremoved.这也有助于金属完全填充模具模膛。锻造后，要将飞边去除。2.closed-dieforging/Impression-dieforgingExcessmetalissqueezedoutoExcessmetalissqueezedoutoIncommercialimpression-dieforging,theworkpieceisusuallymovedthroughaseriesofcavitiesinadietogetfromaningottothefinalform.大多数的商用闭模锻件，工件从铸锭到成品实际是连续流经一个模具中的多个模膛的过程。(多膛锻模)Thefirstimpressionisusedtodistributethemetalintotheroughshapeinaccordancetotheneedsoflatercavities;thisimpressioniscalledan"edging","fullering",or"bending"impression.第一种模膛(制坯模膛)将金属锻造为与后续模膛的需要粗略一致的形状。这种模膛被称为“切断模膛”,“成型模膛”,“弯曲模膛”等。2.closed-dieforging/Impression-dieforgingIncommercialimpression-diefIncommercialimpression-diefThefirstimpression:2.closed-dieforging/Impression-dieforgingThefirstimpression:2.closedThefirstimpression:2.closedThefollowingcavitiesarecalled"blocking"cavities,inwhichthepieceisworkingintoashapethatmorecloselyresemblesthefinalproduct.下一个模膛叫“预锻模膛”，工件在这里被加工至与最终产品更加接近。Thefinalshapeisforgedina"final"or"finisher"impressioncavity.Ifthereisonlyashortrunofpartstobedone,thenitmaybemoreeconomicalforthedietolackafinalimpressioncavityandinsteadmachinethefinalfeatures.最后的形状在“终锻模膛”中锻造获得。如果是进行小批量生产，则更经济的做法是在模具中不设终锻模膛而改用机械加工获取最终的产品特征。2.closed-dieforging/Impression-dieforgingThefollowingcavitiesarecalThefollowingcavitiesarecalclosed-dieforging

aseriesofcavitiesclosed-dieforging

aseriesoclosed-dieforging

aseriesoAdvantage：canproducecomponentsofgreatercomplexityandaccuracy,withabettersurfacefinish,thanthemoretraditionalmethodsnotusingcloseddies.2.closed-dieforging/Impression-dieAdvantage：canproducecomponenAdvantage：canproducecomponen1.thehydraulicforgingpressisamoreexpensivepieceof

equipmentthanadrop-forge.2.thehydraulicforginggivesgreaterstrengthandmoreuniformstructuretolargecomponents.3.Onaccountofthehighpressureandsqueezingaction,it

operateswithlessnoiseandvibrationthanadrop-forge.4.manualoperationisimpossibleanditisessentialthatallthe

manipulationoftheingotisdonemechanically.hydraulicforging&drop-forge1.thehydraulicforgingpress1.thehydraulicforgingpressAdvantageofForging？Forgingcanproduceapiecethatisstrongerthananequivalent

cast

or

machined

part.锻件比同等铸件和机加件强度高。Asthemetalisshapedduringtheforgingprocess,itsinternal

grain

deformstofollowthegeneralshapeofthepart.Asaresult,thegrainiscontinuousthroughoutthepart,givingriseto(产生,导致)apiecewithimprovedstrengthcharacteristics.AdvantageofForging？AdvantageofForging？AdvantagVideo-各种锻造Video-各种锻造Video-各种锻造Video-各种锻造ForgingprocessesForgingprocessesForgingprocessesForgingproForgingProcessesHistoryofForging？Forgingisoneoftheoldestknownmetalworkingprocesses.Traditionally,forgingwasperformedbya

smith

usinghammerand

anvil(铁砧),thoughintroducingwaterpowertotheproductionandworkingofironinthe12thcenturydrovethehammerandanvilintoobsolescence(过时，淘汰).Video-hammerandanvilForgingProcessesHistoryofForgingProcessesHistoryofUnit4ForgingProcesses

WhatisForging？Itisanimportanthot-formingprocess.Itisusedinproducingcomponentsofallshapesandsizes,fromquitesmallitemstolargeunitsweighingseveraltons.锻造是一种重要的热成型工艺。用于生产各种形状和尺寸的零件，有的极小有的重达几吨。Itistheprocessbywhichmetalisheatedandisshapedbyplasticdeformationbysuitablyapplyingcompressiveforce.在此过程中金属被加热，通过适当应用压力产生塑性变形使金属成型。(video-largepartsforging)Unit4ForgingProcessesWhUnit4ForgingProcessesWh

Handforgingtoolscomprisevariouslyshaped

hammers.手工锻造工具包括各种不同形状的锤子。①Forthesemimechanizedforgingofsmalltomedium-sizedcomponents,forginghammerspoweredbyvariousmeansareemployed.对小到中等尺寸零件的半机械化锻造而言，采用锻锤，锻锤的驱动动力有多种方式。video-swordThefeaturecommontoallofthemisthat,likethehandforginghammer,theyutilizetheenergyofafallingweighttodevelopthepressureneededforshapingthemetal.无论采用什么样的驱动力，它们共同的特点就是(和手工锻锤一样)，都是利用落重能量来产生金属成型所需的压力。ForgingtoolsHandforgingtoolscomprisevHandforgingtoolscomprisev②Largercomponentsareforgedbymeansofforgingpressesoperatedbysteamorcompressedairorbyhydraulicorelectricpower.锻造大零件则要用到蒸汽、压缩空气、液力或电力驱动的锻压机。Largelyautomaticforgingmachinesareusedforthequantityproductionofengineeringparts.大型的自动化锻机用于工程零件的批量生产。Forgingtools②Largercomponentsareforged②LargercomponentsareforgedClassificationofforgingTherearemanydifferentkindsofforgingprocessesavailable,howevertheycanbegroupedintothreemainclasses:Drawnout:lengthincreases,cross-section

decreasesUpset:lengthdecreases,cross-sectionincreasesSqueezedinclosedcompressiondies:producesmultidirectionalflowDrawnout拔长cross-section横截面Upset镦粗Squeezed挤压,塞进

compressiondies压模closedcompressiondies封闭压模Video-拔长ClassificationofforgingVideoClassificationofforgingVideoDropForging落锻，落锤锻造Open-DieForging/HandForging开模段，手工锻，自由锻Closed-DieForging/Impression-DieForging/PrecisionForging闭模锻，模锻，精锻PressForgings

压力锻造UpsetForgings顶锻，镦锻RollForgings滚锻,辊锻Swaging（型锻,模锻,挤锻）NetShape/Near-NetShapeForgings精锻,纯型锻CommonForgingProcessesDropForging落锻，落锤锻造CommonForDropForging落锻，落锤锻造CommonForDropforgingisaforgingprocesswhereahammerisraisedandthen"dropped"ontotheworkpiecetodeformitaccordingtotheshapeofthedie.落锻过程即锻锤抬起再“落下”，落至工件使之变形。Therearetwotypesofdropforging:open-diedropforgingandclosed-diedropforging.有两种落锻：开模落锻和闭模落锻Asthenamesimply,thedifferenceisintheshapeofthedie,withtheformernotfullyenclosingtheworkpiece,whilethelatterdoes.顾名思义，两者之间区别在于模具的形状。开模锻没有完全封闭式包围工件，闭模锻却有。DropForging落锻，落锤锻造DropforgingisaforgingprocDropforgingisaforgingprocOpen-dieforgingisalsoknownas

smithforging.开模锻（自由锻）又称为铁匠的锻造Inopen-dieforging,ahammerstrikesanddeformstheworkpiece,whichisplacedonastationaryanvil.在开模锻中，工件放置在固定的铁砧上，由铁锤击打工件使之变形，Open-dieforginggetsitsnamefromthefactthatthedies(thesurfacesthatareincontactwiththeworkpiece)donotenclosetheworkpiece,allowingittoflowexceptwherecontactedbythedies.开模锻得名是因为模具没有封闭工件，使得工件可以自由流动（与模具接触的地方除外）1.open-dieforging开模段，手工锻，自由锻Open-dieforgingisalsoknownOpen-dieforgingisalsoknownTherefore,theoperator,needstoorientandpositiontheworkpiecetogetthedesiredshape.

因此操作者需要对工件进行定位和放置动作，才能获得需要的形状。1.open-dieforging开模段，手工锻，自由锻Therefore,theoperator,needsTherefore,theoperator,needsThediesareusuallyflatinshape,butsomehaveaspeciallyshapedsurfaceforspecializedoperations.Forexample,adiemayhavearound,concave,orconvexsurfaceorbeatooltoformholesorbeacut-offtool.自由锻的模具通常是平面，但在特殊操作中也会用到特殊形状表面。例如圆形表面，凹面，凸面，或是制孔工具，切断工具。1.open-dieforging开模段，手工锻，自由锻ThediesareusuallyflatinsThediesareusuallyflatinsOpen-dieforgingscanbeworkedintoshapeswhichincludediscs,hubs,blocks,shafts(includingstepshaftsorwithflanges),sleeves,cylinders,flats,hexes,rounds,plate,andsomecustomshapes.自由锻件可以被加工为各种形状，包括阀盘，衬套，块，轴(包括阶梯轴或带法兰盘的轴)，套筒，圆柱体，平板，六角形，圆形物，盘类，及一些自定义形状。1.open-dieforging开模段，手工锻，自由锻Video-球体Open-dieforgingscanbeworkeOpen-dieforgingscanbeworke

Open-dieforginglendsitselfto

shortrunsandisappropriateforartsmithingandcustomwork.手工锻适用于小批量生产，艺术锻造，及定制工作。Insomecases,open-dieforgingmaybeemployedtorough-shapeingots

topreparethemforsubsequentoperations.在一些情况下，自由锻被用于为机械加工等后续操作准备粗略成型的坯料。lenditselfto适宜于shortrun小批量Ingot锭，铸块1.open-dieforging开模段，手工锻，自由锻

Open-dieforginglendsitself

Open-dieforginglendsitselfItisverywidelyusedformassproduction

inindustry,inwhichthemetalisshapedbypressingbetweenapairofforgingdies.闭模锻广泛用于工业大批量生产，金属在一对锻模之间挤压成型。

Makeup：Theupperdieisusuallyattachedtotheram（撞头）ofaforgingpressoraforginghammer,whilethelowerdieisstationary.Togethertheyformacloseddie.Themetalisplacedinthelowerdie.组成：顶模通常附着在锻压机的撞头或锻锤上，底模则固定不动。金属就放置在底模上。2.closed-dieforging/Impression-dieforgingItisverywidelyusedformasItisverywidelyusedformasThehammeristhendroppedontheworkpiece,causingthemetaltoflowandfillthediecavities.锻锤落至工件，使得金属流动并填充模具模膛。Thehammerisgenerallyincontactwiththeworkpieceonthescaleofmilliseconds.Dependingonthesizeandcomplexityofthepart,thehammermaybedroppedmultipletimesinquicksuccession.通常锻锤和工件接触的速度以毫秒计。根据零件的尺寸和复杂性，锻锤快速连续地多次落锤。2.closed-dieforging/Impression-dieforgingThehammeristhendroppedonThehammeristhendroppedonExcessmetalissqueezedoutofthediecavities,formingwhatisreferredtoas"flash".多余的金属从模具模膛中挤出，形成所谓的“飞边”。Theflashcoolsmorerapidlythantherestofthematerial;thiscoolmetalisstrongerthanthemetalinthedie,soithelpspreventmoreflashfromforming.飞边的冷却速度比其余速度快。冷却后的飞边比模具内的金属强度大，从而防止形成更多的飞边。Thisalsoforcesthemetaltocompletelyfillthediecavity.Afterforging,theflashisremoved.这也有助于金属完全填充模具模膛。锻造后，要将飞边去除。2.closed-dieforging/Impression-dieforgingExcessmetalissqueezedoutoExcessmetalissqueezedoutoIncommercialimpression-dieforging,theworkpieceisusuallymovedthroughaseriesofcavitiesinadietogetfromaningottothefinalform.大多数的商用闭模锻件，工件从铸锭到成品实际是连续流经一个模具中的多个模膛的过程。(多膛锻模)Thefirstimpressionisusedtodistributethemetalintotheroughshapeinaccordancetotheneedsoflatercavities;thisimpressioniscalledan"edging","fullering",or"bending"impression.第一种模膛(制坯模膛)将金属锻造为与后续模膛的需要粗略一致的形状。这种模膛被称为“切断模膛”,“成型模膛”,“弯曲模膛”等。2.closed-dieforging/Impression-dieforgingIncommercialimpression-diefIncommercialimpression-diefThefirstimpression:2.closed-dieforging/Impression-dieforgingThefirstimpression:2.closedThefirstimpression:2.closedThefollowingcavitiesarecalled"blocking"cavities,inwhichthepieceisworkingi