The casting-forging combined technique and the closed die forging without flash-less are both new developed material working methods. The former can not only decrease forming operations of forgings, but also increase ...The casting-forging combined technique and the closed die forging without flash-less are both new developed material working methods. The former can not only decrease forming operations of forgings, but also increase the material utilization ratio. Therefore, it is applied to produce more complex forgings. The latter is required for forging precise parts without burrs. The alternator pole is a complex forging, which was usually produced by hot forging, upsetting-extrusion or upsetting-extrusion and bending processes. During these processes, not only the forming force is higher, but the material of burrs accounts for 30 percent or so of total required material. And burrs are difficult to remove in the sequential machining process. In accordance with defects exiting in current manufacturing of alternator poles by upsetting-extruding process, such as more material demand, higher forming force and difficulty of next machining, a casting-forging precision process of alternator poles was developed and investigated in this paper. In the process, the pole was formed by two operations. One is the pre-forming operation by casting. The other is the final forming operation by the closed precision forging process. This can not only shorten processes, decrease material and power demand, but also increase precision of forgings. First, the casting blocker was designed considering the casting process and the forging ratio and the mode of deformation. Then the die structure for closed precision forging was designed, and the closing device for forging dies with spring assemblies in order to provide the necessary closing force was also designed. Finally the forming processes was investigated by test and numerical simulation method to optimum process parameters and die structure design parameters. The result can provide basis for applying the process to manufacture poles in practice.展开更多
We proposed the flat-type permanent magnet linear alternator (LA) for free piston linear alternators (FPLAs) instead of the tubular one. Using the finite element method (FEM), we compare these two kinds of LAs. The FE...We proposed the flat-type permanent magnet linear alternator (LA) for free piston linear alternators (FPLAs) instead of the tubular one. Using the finite element method (FEM), we compare these two kinds of LAs. The FEM result shows that the flat-type permanent magnet LA has higher efficiency and larger output specific power than the tubular one, therefore more suitable for FPLAs, and that the alternator design can be optimized with respect to the permanent magnet length as well as the air gap.展开更多
文摘The casting-forging combined technique and the closed die forging without flash-less are both new developed material working methods. The former can not only decrease forming operations of forgings, but also increase the material utilization ratio. Therefore, it is applied to produce more complex forgings. The latter is required for forging precise parts without burrs. The alternator pole is a complex forging, which was usually produced by hot forging, upsetting-extrusion or upsetting-extrusion and bending processes. During these processes, not only the forming force is higher, but the material of burrs accounts for 30 percent or so of total required material. And burrs are difficult to remove in the sequential machining process. In accordance with defects exiting in current manufacturing of alternator poles by upsetting-extruding process, such as more material demand, higher forming force and difficulty of next machining, a casting-forging precision process of alternator poles was developed and investigated in this paper. In the process, the pole was formed by two operations. One is the pre-forming operation by casting. The other is the final forming operation by the closed precision forging process. This can not only shorten processes, decrease material and power demand, but also increase precision of forgings. First, the casting blocker was designed considering the casting process and the forging ratio and the mode of deformation. Then the die structure for closed precision forging was designed, and the closing device for forging dies with spring assemblies in order to provide the necessary closing force was also designed. Finally the forming processes was investigated by test and numerical simulation method to optimum process parameters and die structure design parameters. The result can provide basis for applying the process to manufacture poles in practice.
基金Project (No. 50806046) supported by the National Natural Science Foundation of China
文摘We proposed the flat-type permanent magnet linear alternator (LA) for free piston linear alternators (FPLAs) instead of the tubular one. Using the finite element method (FEM), we compare these two kinds of LAs. The FEM result shows that the flat-type permanent magnet LA has higher efficiency and larger output specific power than the tubular one, therefore more suitable for FPLAs, and that the alternator design can be optimized with respect to the permanent magnet length as well as the air gap.
