During the conventional disk-forging, the upper die repeatedly compresses materials on the flat stationary base. As the strain distributions of the forged disk are non-uniform owing to friction and uneven temperature distribution, more uniform deformation within the entire volume is desirable to obtain sound disk free from defects. This study proposes an advanced disk-forging process in the production of a defect-free heavy disk using counteracting dies. An industry-applicable disk-manufacturing process using a conventional single die-forging process and a proposed counteracting die were characterized and compared based on variations in geometries with successive forging steps. Variations in stress, equivalent strain, and temperature were obtained through three-dimensional finite element simulations using FORGE™ software, during the disk-forging processes of cylindrical preforms. Comparison of the simulation results indicated that the proposed forging process using counteracting dies was highly effective in producing sound disks having uniform microstructure without process-induced defects. The shop-floor production was performed to validate the proposed process, and the feasibility of the process was demonstrated based on the forged disk qualities that were assessed by non-destructive examination and mechanical testing. The test data showed that the defect-free disk with uniform mechanical properties was successfully produced through the proposed forging process using counteracting dies.

在传统的圆盘锻造过程中，上模会反复压缩平坦的固定基座上的材料。由于由于摩擦和温度分布不均匀而导致的锻造盘的应变分布不均匀，因此希望在整个体积内更均匀地变形以获得没有缺陷的声盘。这项研究提出了一种先进的盘锻造工艺，该工艺可以使用冲模来生产无缺陷的重盘。使用传统的单模锻工艺和建议的反冲模，对行业适用的磁盘制造工艺进行了表征，并根据几何形状的变化和连续的锻造步骤进行了比较。使用FORGE™软件通过三维有限元模拟获得应力，等效应变和温度的变化，在圆柱形预成型件的盘锻过程中。模拟结果的比较表明，所建议的使用抵消模具的锻造工艺在生产具有均匀微观结构而没有工艺引起的缺陷的声盘方面非常有效。进行车间生产以验证所提议的过程，并基于通过无损检查和机械测试评估的锻造盘质量，证明了该过程的可行性。测试数据表明，通过使用抵消模具的拟议锻造工艺成功生产了具有均匀机械性能的无缺陷圆盘。模拟结果的比较表明，所提出的使用抵消模具的锻造工艺在生产具有均匀微观结构而没有工艺引起的缺陷的音盘方面非常有效。进行车间生产以验证所提议的过程，并基于通过无损检查和机械测试评估的锻造盘质量，证明了该过程的可行性。测试数据表明，通过使用抵消模具的拟议锻造工艺成功生产了具有均匀机械性能的无缺陷圆盘。模拟结果的比较表明，所提出的使用抵消模具的锻造工艺在生产具有均匀微观结构而没有工艺引起的缺陷的音盘方面非常有效。进行车间生产以验证所提议的过程，并基于通过无损检查和机械测试评估的锻造盘质量，证明了该过程的可行性。测试数据表明，通过使用抵消模具的拟议锻造工艺成功生产了具有均匀机械性能的无缺陷圆盘。基于无损检测和机械测试评估出的锻造盘质量，证明了该工艺的可行性。测试数据表明，通过使用抵消模具的拟议锻造工艺成功生产了具有均匀机械性能的无缺陷圆盘。基于无损检测和机械测试评估出的锻造盘质量，证明了该工艺的可行性。测试数据表明，通过使用抵消模具的拟议锻造工艺成功生产了具有均匀机械性能的无缺陷圆盘。