Apparatus for manufacturing parts, and related methods

Patent metadata

Field	Value
Publication number	US-11305332-B2
Application number	US-202117155587-A
Country	US
Kind code	B2
Filing date	Jan 22, 2021
Priority date	Jun 1, 2018
Publication date	Apr 19, 2022
Grant date	Apr 19, 2022

Abstract

Forging dies are formed from a plurality of layers stacked together to form an assembly, or laminate. Each respective layer may be cut to form a portion of a die cavity, and the layers may be stacked together such that the cut portions are aligned to form the die cavity. The layers are fastened together to form a first die half and/or a second die half of disclosed forging dies. Each layer may be selectively removable from the die half for maintenance and/or replacement. Disclosed forging dies may be formed of lower grade materials as compared to conventional forging dies, and the number and thickness of layers may be varied to accommodate the specific part geometry of the part being forged. Related methods of making said forging dies and using said forging dies to make parts are also disclosed.

First claim

The invention claimed is:

1. A forging die for forging a part from a preform, the forging die comprising:
a first die half, wherein the first die half comprises:
a first layer cut to form a first portion of a first die cavity;
a second layer cut to form a second portion of the first die cavity, wherein the first layer and the second layer are configured to be stacked together such that the first portion of the first die cavity and the second portion of the first die cavity are positioned with respect to one another to form the first die cavity; and
a first plurality of fasteners fastening the first layer and the second layer together to form the first die half, wherein each fastener of the first plurality of fasteners extends through at least a portion of each of the first layer and the second layer, wherein each fastener of the first plurality of fasteners is selectively removable from the first die half, and wherein the first plurality of fasteners are sized and placed with respect to the first die half such that the first plurality of fasteners is configured to prevent introduction of material from the preform into spaces between adjacent respective layers of the first die half during forging of the part without bonding, brazing, or welding the first layer and the second layer together; and

a second die half, wherein the second die half and the first die half are configured to cooperate with one another such that the first die cavity faces the second die half and such that the first die cavity is configured to receive at least a portion of the preform, and wherein the forging die is configured to forge the part from the preform when the first die half and the second die half are pressed together.

2. The forging die according to claim 1 , wherein the second die half comprises:
a third layer cut to form a first portion of a second die cavity;
a fourth layer cut to form a second portion of the second die cavity, wherein the third layer and the fourth layer are configured to be stacked together such that the first portion of the second die cavity and the second portion of the second die cavity are positioned with respect to one another to form the second die cavity; and
a second plurality of fasteners fastening the third layer and the fourth layer together to form the second die half, wherein each fastener of the second plurality of fasteners extends through at least a portion of each of the third layer and the fourth layer, and wherein each fastener of the second plurality of fasteners is selectively removable from the second die half;
wherein the second die half and the first die half are configured to cooperate with one another such that the first die cavity faces the second die cavity and such that the first die cavity and the second die cavity are each configured to receive a respective portion of the preform, and wherein the forging die is configured to forge the part from the preform when the first die half and the second die half are pressed together.

3. The forging die according to claim 2 , wherein the second plurality of fasteners are of a sufficient second number, size, and/or placement such that the second plurality of fasteners are configured to prevent introduction of material from the preform into spaces between adjacent respective layers of the second die half during forging of the part.

4. The forging die according to claim 2 , wherein the first die half comprises one or more additional first die layers each cut to form an additional respective portion of the first die cavity, wherein each additional first die layer is configured to be stacked between the first layer and the second layer such that the additional respective portions of the first die cavity are positioned with respect to the first portion of the first die cavity and the second portion of the first die cavity, to form the first die cavity, and wherein the second die half comprises one or more additional second die layers each cut to form an additional respective portion of the second die cavity, wherein each additional second die layer is configured to be stacked between the third layer and the fourth layer such that the additional respective portions of the second die cavity are positioned with respect to the first portion of the second die cavity and the second portion of the second die cavity, to form the second die cavity.

5. The forging die according to claim 4 , wherein the first die half comprises a first baseplate secured to the second layer, wherein the first baseplate is thicker than the first layer and the second layer, and wherein the first baseplate does not form a portion of the first die cavity, wherein the second die half comprises a second baseplate secured to the fourth layer, wherein the second baseplate is thicker than the third layer and the fourth layer, wherein the second baseplate does not form a portion of the second die cavity, and wherein the first baseplate of the first die half and the second baseplate of the second die half are positioned opposite one another, with the first die cavity and the second die cavity positioned therebetween.

6. The forging die according to claim 5 , wherein the first plurality of fasteners are further configured to bind the first baseplate, the first layer, the second layer, and the additional first die layers together, wherein each respective fastener of the first plurality of fasteners extends through at least a portion of each respective layer to form the first die half, wherein the second plurality of fasteners are further configured to bind the second baseplate, the third layer, the fourth layer, and the additional second die layers together, and wherein each respective fastener of the second plurality of fasteners extends through at least a portion of each respective layer to form the second die half.

7. The forging die according to claim 4 , wherein the one or more additional first die layers have varying thicknesses to accommodate loads and stresses during forging of the part, and further wherein the one or more additional second die layers have varying thicknesses to accommodate loads and stresses during forging of the part.

8. The forging die according to claim 4 , wherein each respective layer of the first die half is selectively removable from the first die half by removing the first plurality of fasteners.

9. The forging die according to claim 8 , wherein each respective layer of the second die half is selectively removable from the second die half by removing the second plurality of fasteners.

10. The forging die according to claim 9 , further comprising a replacement layer, wherein the replacement layer is configured to be inserted into the forging die to replace a worn layer that has been removed from the first die half or the second die half, and wherein the replacement layer is cut to correspond to the worn layer removed from the forging die.

11. The forging die according to claim 2 , wherein the first layer is formed of a first material, wherein the second layer is formed of a second material, wherein the third layer is formed of a third material, wherein the fourth layer is formed of a fourth material, wherein the first material is more wear-resistant, has a higher hardness, has a higher tensile and/or compression strength, and/or has a higher toughness than the second material, and wherein the third material is more wear-resistant, has a higher hardness, has a higher tensile and/or compression strength, and/or has a higher toughness than the fourth material.

12. The forging die according to claim 1 , further comprising a sensor encapsulated in the first die half and/or the second die half, wherein the sensor is configured to moni

Assignees

• Boeing Co

Inventors

• Heck David P
• Slattery Kevin Thomas
• Milliken David M

Classifications

• B21J13/02 Primary

  Dies or mountings therefor · CPC title

• B21J5/025 Primary

  Closed die forging · CPC title

• B23P15/246

  Laminated dies · CPC title