Manufacturing method for material for ring rolling

Abstract

A manufacturing method provides a high-quality material for ring rolling. The manufacturing method of the material for ring rolling includes a step of heating a disk-shaped material for hot forging to a hot working temperature, a step of arranging the material for hot forging onto a lower die having a convex portion with a truncated conical shape, a step of forming a thin portion by pressing a center portion of the material for hot forging by using an upper die having a convex portion with a truncated conical shape, and a step of manufacturing a material for ring rolling by removing the thin portion wherein a center of gravity on a half section of the material for ring rolling is located so as to be closer to an outer peripheral surface of the half section than a center of the half section in a thickness direction of the half section.

Claims

1. A manufacturing method for a material for ring rolling, to be shaped by rolling, to manufacture a ring product to be used in high temperature environments, the manufacturing method comprising: heating a disk-shaped material for hot forging to a hot working temperature; forming a portion having a reduced thickness in the disk-shaped material by pressing a center portion of the disk-shaped material with an upper die having a convex portion with a truncated conical shape and a lower die having a convex portion with a truncated conical shape; and manufacturing the material for ring rolling by removing the portion having the reduced thickness, wherein a shape of a half section of the material for ring rolling includes a shape forming: a height reducing portion having a height from a center line which divides the half section into halves in a height direction of the half section, gradually reduced toward an inner peripheral surface of the material for ring rolling, and a linear portion including end surfaces which are respectively positioned upward and downward and respectively have constant heights, and wherein the height reducing portion and the end surfaces of the linear portion are shaped during the forming of the portion having the reduced thickness by the pressing with the upper die and the lower die; wherein a center of gravity on the half section of the material for ring rolling is located so as to be closer to an outer peripheral surface of the material for ring rolling than a center of the half section in a thickness direction of the half section, wherein the material for ring rolling is formed such that a shape of the half section includes the height reducing portion having the height from the center line which divides the half section into halves in the height direction is gradually reduced toward the inner peripheral surface and the shape of the half section is formed in a substantially linear symmetry so as to define the center line as a symmetrical axis of the half section, and wherein a height of the inner peripheral surface is from 20% to 50% of a maximum height of the material for ring rolling.

Description

BRIEF DESCRIPTION OF DRAWINGS

(1) FIG. 1 is a cross section that schematically illustrates a process of forming a material for ring rolling according to the manufacturing method of the present invention.

(2) FIG. 2 is a half sectional view which schematically shows an example of the material for ring rolling obtained by the manufacturing method of the present invention.

(3) FIG. 3 is a half sectional view which schematically shows an example of the material for ring rolling obtained by the manufacturing method of the present invention.

(4) FIG. 4 is a half sectional view which schematically shows an example of the material for ring rolling obtained by the manufacturing method of the present invention.

(5) FIG. 5 is a half sectional view which schematically shows an example of the material for ring rolling obtained by the manufacturing method of the present invention.

(6) FIG. 6 is a cross sectional view which schematically illustrates an example of upper and lower molds used in producing the material for ring rolling.

(7) FIG. 7 is a cross sectional view which schematically shows an example of upper and lower dies used when manufacturing the material for ring rolling.

(8) FIG. 8 is a cross sectional view which schematically shows an example of upper and lower dies used when manufacturing the material for ring rolling.

(9) FIG. 9 is a cross sectional view which schematically shows an example of upper and lower dies used when manufacturing the material for ring rolling.

(10) FIG. 10 is a perspective view which schematically illustrates a rolling process for the material for ring rolling.

(11) FIG. 11 is a diagram which shows temperature distribution obtained by numerical analyses practiced for cases of ring rollings which are respectively performed by using a material for ring rolling obtained by the manufacturing method according to the present invention, and a material for ring rolling of a Comparative Example.

(12) FIG. 12 is a diagram which shows distortion distribution obtained by numerical analysis practiced for cases of ring rollings which are respectively performed by using a material for ring rolling obtained by the manufacturing method according to the present invention, and a material for ring rolling of the Comparative Example.

(13) FIG. 13 is a diagram which shows a metal structure of an upper portion, an inner diameter portion, a center portion, an outer diameter portion, and a lower portion of the material for ring rolling obtained by the manufacturing method according to the present invention by macrophotographs.

DESCRIPTION OF EMBODIMENT

(14) An Embodiment of the present invention will be described while seeing attached drawings, as follows.

(15) The present invention will be described below with reference to the attached drawings.

(16) (Forming of Material for Ring Rolling)

(17) A material for ring rolling which is used for each disk with a diameter of Φ 1000 mm or more for a gas turbine, will be described as an example of an Embodiment of the present invention. A Ni-based superalloy having excellent high temperature strength is employed as the material for ring rolling. Hereinbelow, an example in which the Ni-based superalloy equivalent to a 718 alloy is used as the material, will be described, and note that as an example of components of the Ni-based superalloy, the Ni-based superalloy has a component structure including 50% to 55% by mass of Ni, 15% to 22% by mass of Cr, 4.5% to 6.5% by mass of Nb, 2.5% to 3.5% by mass of Mo, 0.6% to 1.2% by mass of Ti, and 0.2% to 0.8% by mass of Al, and the other portions constituted by Fe and inevitable impurities.

(18) As shown in FIG. 1(a), a Ni-based superalloy 1 having a disk-shape and a predetermined height is heated to a hot process temperature. Note that for the hot process temperature, temperature may be determined according to material characteristics of the material for ring rolling. For example, if the material is a Ni-based superalloy, temperature ranging from 900 degrees C. to 950 degrees C. is suitable. If a high strength stainless steel material is used, temperature ranging from 850 degrees C. to 900 degrees C. is preferable.

(19) Next, the material made of the Ni-based superalloy is arranged at a lower die having a convex portion with the truncated conical shape. In arranging the material, it is easiest to place it onto the lower die. In addition, as shown in FIG. 1(b), the Ni-based superalloy 1 is then pressed in a center thereof as shown in FIG. 1(b), by using upper and lower dies (upper and lower molding dies) 2, 3, and note that the upper and lower dies 2, 3 are provided in a hot forging apparatus, a hot pressing apparatus, and the like, and they have the convex portion with the shape of the truncated cone in their center so that a thin portion 4 (a portion shown in FIG. 1(b) as a hatched portion) having a space for a concave portion with a shape of a truncated cone is formed. After that, the thin portion provided in the center is cut off so as to form the material for ring rolling. Note that the material can be formed so as to have a desired shape by machining after cutting off the thin portion 4. For the method of cutting off the thin portion, known methods, such as machining and cutting with a waterjet cutter, can be used.

(20) Furthermore, in the present invention, the hot-worked material obtained after the hot working can be used such that it is as the material for ring rolling, and therefore, it is important to form the concave portion of the Ni-based superalloy material on the center thereof with high accuracy. For the method intended for this order, the following method may be used, that is to say, in this method, the convex shape and the concave shape which can be engaged with each other, are respectively formed on the Ni-based superalloy material and on the lower die on which the Ni-based superalloy material is to be placed, and alignment (centering) between the material and the dies can be practiced by engaging the convex shape and the concave shape to each other. As another alternative method, a method may be used, in which an alignment mechanism provided in a manipulator, is used to place the Ni-based superalloy material onto the center of the lower die.

(21) In addition, a hot forging apparatus is used as the hot working machine applied in the present invention. Note that hot forging includes hot pressing, and also includes isothermal forging.

(22) (Shape of Material for Ring Rolling)

(23) FIG. 2 shows an example of a half section of the material 11 for ring rolling obtained by the abovedescribed forming process of the material for ring rolling. In FIG. 2, a direction along a central axis CA of the material 11 for ring rolling is defined as a “height direction”, and a direction perpendicular to the central axis CA is defined as a “thickness direction”. Note that in FIGS. 3 to 5 to be described as follows, the expressions “height direction” and “thickness direction” denote the same direction as those indicated in FIG. 2 respectively.

(24) FIG. 2 is the half sectional view which schematically shows the material 11 for ring rolling shaped so as to have a shape axisymmetric with respect to the central axis CA (Shape 1). In the Embodiment of the present invention, the expression “half sectional view” indicates a view which shows a portion of the material 11 for ring rolling on one side thereof in the thickness direction relative to the central axis CA. That is to say, a left portion of the material 11 for ring rolling is omitted in the drawing.

(25) This material 11 for ring rolling has a radially outer peripheral surface 12 and a radially inner peripheral surface 13. The material 11 for ring rolling includes an outer peripheral portion 14 which has the outer peripheral surface 12. The outer peripheral surface 12 is a part of the peripheral edge of the outer peripheral portion 14, and this part forms a contour of the half section. The outer peripheral portion 14 is located so as to be close to the outer periphery of the material 11 for ring rolling relative to a boundary line (not shown) which linearly connects both end portions 12a of the outer peripheral surface 12 in the height direction.

(26) The shape of the half section of the material 11 for ring rolling shown in the drawing, includes a linear portion 15 provided at a location close to the center portion in the thickness direction. This linear portion 15 includes an end surface 16 which is directed in the height direction and is linearly extended. A length of the linear portion 15, preferably a length of the end surface 16 of the linear portion 15, is approximately ⅔ times of a maximum height H1 of the material 11 for ring rolling. A height reducing portion 17 is provided so as to be connected to the linear portion 15. This height reducing portion 17 is formed so as to have a tapered shape, and a height of the height reducing portion 17 from a center line CL which divides the half section into halves in the height direction, is gradually reduced toward the inner peripheral surface 13 which is in contact with a mandrel roll.

(27) A height Hin on a side of an end of the inner diameter (the inner peripheral surface 13) is equal to or more than ⅓ times (33%) of the maximum height H1 of the material 11 for ring rolling and equal to or less than ½ times (50%) thereof. In addition, a length of the height reducing portion 17 in the thickness direction, preferably a length of a line that a slanted surface 18 of the height reducing portion 17 extending from a highest point of the height of the material 11 for ring rolling, is projected on the center line CL in the height direction, is set within a range which is from 0.2 times to 1.5 times of the maximum height H1 of the material 11 for ring rolling. Furthermore, the height reducing portion 17 is formed so as to have the following shape, and that is to say, the shape is tapered from the both end portions 12a of the outer peripheral surface 12 in the height direction, which is formed on the side of the main roll, toward both end portions 13a of the inner peripheral surface 13 in the height direction, while the shape includes a linear-shaped portion having a predetermined length. The shape of the half section is also substantially linearly symmetrical so as to define the center line CL as a symmetrical axis. Note that a center of gravity (or a center of the figure) G on the half section of the material 11 for ring rolling is located so as to be closer to the main roll from a center CP of the material 11 for ring rolling in the thickness direction, i.e., is located on a side of the outer peripheral surface 12. In the drawing, the center CP in the thickness direction is indicated by an x mark, and the location of the center of gravity G is indicated by a solid circle.

(28) Note that in manufacturing the material for ring rolling shown in FIG. 2, for example, it is preferable to use the upper die 2 and the lower die 3 shown in FIG. 6. In this regard, it is preferable to set an angle of the convex portion which has the truncated conical shape formed on the center thereof, (angle θ) in a range of 20 degrees to 70 degrees. This is because if the angle is less than 20 degrees, a thickness of the material for ring rolling after the manufacturing thereof, may be excessively increased so that time for the ring rolling may be increased, and on the other hand, if the angle is greater than 70 degrees, it is not sufficient to flow material into a portion between the Ni-based superalloy material and the convex portion with the truncated conical shape during hot forging so that a desired shape may not be obtained in some cases. A lower limit of the angle θ is preferably 25 degrees. An upper limit of the angle θ is preferably 45 degrees, and is more preferably 30 degrees.

(29) FIGS. 3 to 5 show a First Modification to a Third Modification of the material 11 for ring rolling respectively.

(30) To begin with, in the half sectional view of the material 11 for ring rolling of the First Modification shown in FIG. 3 (Shape 2), an upper portion 12b and a lower portion 12c of the radially outer peripheral surface 12 in the height direction as described above in FIG. 2, include a tapered portion. An intermediate portion 12d which connects the upper and the lower tapered portions, has a linear shape. According to the shape shown in FIG. 3, the upper portion 12b and the lower portion 12c of the outer peripheral surface 12 include the tapered portions respectively, the intermediate portion 12d which connects the upper and the lower tapered portions, is formed so as to have a linear shape, and therefore, a contact area between the main roll and the material 11 for ring rolling at a start of the ring rolling, can be increased so that the ring rolling can be stable.

(31) Examples of methods of which each is used to obtain this shape, include a method in which the shape is arranged by machining after the abovedescribed shape shown in FIG. 1 is obtained. For example, in this method, a set of dies which includes the upper and lower dies 2, 3 and is formed so as to obtain the shape shown in FIG. 3, is used in the abovedescribed forming of the material for ring rolling. If a method in which machining is practiced, is used, accuracy of the shape can be improved, and on the other hand, the production yield may become worse. Therefore, it is advantageous to form (shape) the shape shown in FIG. 3 by using the shape of the die used at a stage of hot forging (including hot pressing).

(32) If the shape of the material 11 for ring rolling shown in FIG. 3, is applied to the shape of the die used at the stage of the hot forging, a distance from the central axis CA of the material 11 for ring rolling to the outer peripheral surface of the main roll, and a distance from the central axis CA of the material 11 for ring rolling to the outer peripheral surface 12, can be set the same as each other by controlling the shape of the die. As a result, the ring rolling can be more stably performed.

(33) Note that if the shape shown in FIG. 3 is shaped by hot forging, a press load becomes higher compared with a case in which the shape shown in FIG. 2 is applied. Accordingly, it can be determined to apply whether the shape shown in FIG. 3 or the shape shown in FIG. 2 while considering a maximum load of the forging apparatus to be used, a maximum load applied during the forging, and the like.

(34) In producing the material for ring rolling shown in FIG. 3, it is preferable to use the upper die 2 and the lower die 3 shown in FIG. 7. In this case, it is preferable to set the angle of the convex portion with the truncated conical shape which is formed in the center thereof, (θ) at an angle within a range of 25 degrees to 35 degrees in the same manner as in the abovedescribed case.

(35) Next, the material 11 for ring rolling of the Second Modification shown in FIG. 4 (Shape 3) has a shape linearly tapered from the both end portions 12a of the outer peripheral surface 12 in the height direction, which is formed on the side of the main roll, toward the both end portions 13a of the inner peripheral surface 13 in the height direction. Examples of methods of which each is used to obtain this shape include a method in which the shape is arranged by machining after the abovedescribed shape shown in FIG. 1 is obtained. For example, in this method, a set of dies which include the upper and lower dies 2, 3 and is formed so as to obtain the shape shown in FIG. 4, is used in the abovedescribed forming of the material 11 for ring rolling. If a method in which machining is practiced, is used, accuracy of the shape can be improved, and on the other hand, the production yield of the material may become worse. Therefore, it is advantageous to form (shape) the shape shown in FIG. 4 by using the shape of the die. Note that in FIG. 4, the outer peripheral surface 12 is formed so as to have a curved surface shape. However, if a part of the curved surface shape which is brought into contact with the main roll first, is worked so as to be flat, a contact area between the main roll and the material 11 for ring rolling at a start of ring rolling, can be increased, and as a result, the ring rolling can be stably performed. Alternatively, as a matter of course, an entire curved surface shape on the side of the outer peripheral surface 12 may be worked so as to be flat.

(36) Note that in producing the material for ring rolling illustrated in FIG. 4, it is preferable to use the upper mold 2 and the lower mold 3 illustrated in FIG. 8. In this case, it is preferable to set the angle of the convex portion with the truncated conical shape formed in the center (θ) at an angle within the range of 15 to 25° C., similar to in the abovedescribed case.

(37) In the material 11 for ring rolling illustrated in the half sectional view in FIG. 5 which shows the Third Modification (Shape 4), the inner peripheral surface 13 in contact with the mandrel roll, is formed so as to have a linear shape, and the other portions are formed so as to have curved surface shapes respectively. To obtain this shape, the material can be shaped by for example, a method in which the upper and the lower dies 2, 3 are formed so as to have the shape shown in FIG. 4 in the abovedescribed forming of the material for ring rolling, or a method in which a height of the convex portion with the truncated cone shape, which is formed on the upper die 2 and on the lower die 3, is increased in the abovedescribed forming of the material for ring rolling.

(38) In addition, in manufacturing the material for ring rolling shown in FIG. 5, for example, it is preferable to use the upper die 2 and the lower die 3 shown in FIG. 9. In this case, it is preferable to set the angle of the convex portion with the truncated conical shape which is formed in the center thereof, (θ) at an angle within a range of 35 degrees to 45 degrees in the same manner as the abovedescribed case. Note that in a case of manufacturing the material for ring rolling shown in FIG. 5, it is preferable to gradually change the angle of the convex portion with the truncated conical shape according to the shape of the height reduction portion with the curved surface shape.

(39) Note that the ring rolling can be more stably performed by using each of the shapes shown in FIGS. 2 and 3 among the shapes shown in FIGS. 2 to 5.

(40) Next, preferable features of shapes of the material 11 for ring rolling according to the Embodiment of the present invention will be described.

(41) As described above, the material 11 for ring rolling has the shape which is tapered toward the side of the inner peripheral surface 13 formed by the height reducing portion 17, and therefore, the center of gravity G in the material 11 for ring rolling is located so as to be closer to the side of the center CP than the center CP of the material 11 for ring rolling in the thickness direction, i.e., is located on the side of the outer peripheral surface 12. According to the abovedescribed shape, the contact area between the mandrel roll and the material 11 for ring rolling can be controlled so as to be smaller. By this feature, the ring rolling can be performed while reducing the load applied during the ring rolling at the same time. Accordingly, in particular, local occurrence of heating on the material 11 for ring rolling which is in contact with the mandrel roll, can be reduced.

(42) In addition, the height Hin of the inner peripheral surface 13 of the material 11 for ring rolling is controlled so as to be from 20% to 50% of the maximum height H1 of the material 11 for ring rolling so that the deformation occurs one after another in the height reducing portion 17 of the material 11 for ring rolling during the ring rolling, and the ring rolling can be performed with a relatively low pressing force. If the height Hin of the inner peripheral surface 13 becomes less than 20% of the maximum height H1 of the material 11 for ring rolling, the contact area between the mandrel roll and the inner peripheral surface 13 is decreased, and therefore, it becomes easy for the material 11 for ring rolling to fall on either of upper side or lower side during the ring rolling so that the ring rolling may become unstable. On the other hand, if the height Hin of the inner peripheral surface 13 exceeds 50% of the maximum height H1 of the material 11 for ring rolling, abnormally high heating may occur. Specifically, if the conditions provided in the Embodiment of the present invention, such as the shape of the section, the location of the center of gravity G, and a relationship between the height Hin of the inner peripheral surface 13 and the maximum height H1 of the material 11 for ring rolling, are appropriately controlled, local occurrence of heating on the material 11 for ring rolling can be suppressed while a hot workability can be enhanced.

(43) Furthermore, in order to more securely obtain the abovedescribed advantageous effects, a lower limit of the height Hin of the inner peripheral surface 13 is preferably 25% of the maximum height H1 of the material 11 for ring rolling, and is more preferably 33% thereof. On the other hand, an upper limit of the height Hin of the inner peripheral surface 13 is preferably 45% of the maximum height H1 of the material 11 for ring rolling, and is more preferably 40% thereof. The expression “height of the inner peripheral surface 13” indicates an interval between the both end portions 13a of the inner peripheral surface 13 in the height direction, which has a curvature of a great difference relative to the curvature of the slanted surface 18 of the height reducing portion 17. For example, in the half sectional views shown in FIGS. 2 to 5, the “height of the inner peripheral surface 13” indicates a length of the linear part in contact with the mandrel roll. Note that even if there is a slightly curved surface or a slightly convex and concave shape on the inner peripheral surface 13 so that it becomes inaccurate to measure the height Hin of the inner peripheral surface 13, the measurement can be performed at a location being within a range which is equal to or less than 20 mm, from the location in contact with the mandrel roll first toward the outer periphery having a curvature of a great difference relative to the curvature of the height reducing portion 17.

(44) As shown in FIGS. 2 to 5, the material 11 for ring rolling is formed in a substantially linearly symmetry so as to define the center line CL as the symmetrical axis. By using the shape which is formed in the substantially linearly symmetry so as to define the center line CL as the symmetrical axis, the ring rolling can be stably performed. Regarding the “substantially linearly symmetry”, for example, if a die in which the outer peripheral surface 12 would not be constrained, is used to perform the shaping of the material for ring rolling in the abovedescribed manner by hot forging, a complete linear symmetry may not be obtained in some cases. Therefore, the expression “substantially linearly symmetry” in the present invention, denotes a shape that may tolerate occurrences of errors, deviations of the shape, and the like in the abovedescribed forming of the material for ring rolling.

(45) Furthermore, in the Embodiment of the present invention, the height reducing portion 17 is provided as shown in FIGS. 2 to 5. The height reducing portion 17 becomes a free space for deformation of the material 11 for ring rolling during the shaping by using a ring rolling mill, and in particular, by this feature, occurrence of excessive heating on the material 11 for ring rolling on the side of the mandrel roll can be prevented. Regarding the height reducing portion 17, as described above, in the Embodiment of the present invention, the height reducing portion 17 can be shaped by pressing in the center thereof while using the upper and the lower dies 2, 3 of which each has the convex portion with a truncated cone shape in the center thereof. In this case, the length of the height reducing portion 17 in the thickness direction becomes longer according to decreasing of the angle of the truncated cone-shaped convex portion. However, if the length of the height reducing portion 17 in the thickness direction is set to be excessively longer, time for working, the height reducing portion 17 during the ring rolling may become longer. On the other hand, according to increasing the angle of the truncated cone-shaped convex portion, the length of the height reducing portion 17 in the thickness direction becomes smaller. However, if the length becomes excessively shorter, a mortar-shaped portion to be cut off after the pressing, is increased, and this may degrade the production yield. In addition, if an area of pressing surface of the convex portion is increased, it becomes necessary to press the die with a higher pressing force, and as a result, it becomes necessary to use a special forging apparatus in which a high load can be applied. In this case, the temperature of the material 11 for ring rolling may become locally high during the ring rolling.

(46) Therefore, in the Embodiment of the present invention, the length of the height reducing portion 17 in the thickness direction, preferably the length of the line obtained by projecting the slanted surface 18 of the height reducing portion 17 onto the center line CL in the height direction, is from 0.2 times to 1.5 times of the maximum height H1 of the material 11 for ring rolling. In this relationship, a lower limit of the length of the height reducing portion 17 in the thickness direction is preferably 0.5 times of the maximum height H1, and is more preferably 0.6 times thereof. On the other hand, an upper limit of the length of the height reducing portion 17 in the thickness direction is preferably 1.1 times of the maximum height H1, and is more preferably 1.0 times thereof.

(47) In the material 11 for ring rolling according to the Embodiment of the present invention, the outer peripheral portion 14 in contact with the main roll is preferably formed so as to have the shape tapered toward the outer periphery.

(48) The material 11 for ring rolling shown in each of FIGS. 2 to 5 is formed so as to have the tapered shape. If the abovedescribed shape is applied, and the dies in which the outer peripheral surface 12 is constrained by hot forging in the shaping of the material for ring rolling, are used, for example, the dies can be used for the ring rolling, and this is economically advantageous. Furthermore, if the outer peripheral surface 12 in contact with the main roll during the ring rolling, has a flat portion as described above, the ring rolling can be stably performed. Accordingly, it is preferable to provide a flat portion in a part of the outer peripheral portion 14 which is in contact with the main roll, in the material 11 for ring rolling. In this feature, it is preferable to provide a flat portion (i.e., a portion of the outer peripheral surface 12 with a linear shape in the drawing) having a length approximately ⅙ times or longer and ⅓ times or shorter of the maximum height H1.

(49) In addition, in the Embodiment of the present invention, the linear portion 15 including both end surfaces in the height direction, which are substantially linearly extended, may be provided between the outer peripheral portion 14 and the height reducing portion 17. Regarding the linear portion 15, if an axial roll is used for the ring rolling, and a flat portion used for pressing by the axial roll is provided, the ring rolling can be performed stably, and a desired shape thereof can be obtain more easily. In this order, a preferable length of the linear portion 15, more preferably a length of the end surface 16 of the linear portion 15, is more than 0 times of the maximum height H1 of the material 11 for ring rolling and is equal to or less than ⅔ times thereof. Although not limiting the present invention particularly, the thickness (material thickness) of the material 11 for ring rolling may be 0.5 times or larger of the maximum height H1 of the material 11 for ring rolling. This limitation is determined while considering a threat of buckling which may occur in subsequent hot forging if the material is excessively thin, because the material 11 for ring rolling according to the Embodiment of the present invention is worked into a shape of a final product by hot forging which is further performed after the ring rolling (the hot forging which includes a forging and a pressing at a hot temperature and a constant temperature).

(50) The angle in the material 11 for ring rolling, which is indicated as “θin”, is preferably equal to or more than 20 degrees. If the angle θin is less than 20 degrees, the height reducing portion 17 becomes longer, and this may lead to increase of time for ring rolling. In this case, weight of the thin portion 4 to be cut off after the hot working, such as hot forging and hot pressing, may be increased, and as a result, this may also degrade the production yield. On the other hand, if the angle θin exceeds 70 degrees, it becomes easy for local heating to occur on the radially inner periphery surface during the ring rolling. In this case, since the Ni-based superalloy 1 would not fully extend inside the upper and the lower dies 2, 3 during the hot working, it becomes difficult to obtain the desired shape thereof. A lower limit of the angle θin at which these problems can be more securely prevented, is preferably 25 degrees. An upper limit of the angle θin is preferably 45 degrees, and is more preferably 30 degrees.

(51) (Ring Rolling Process Performed in Forming Heat-Resistant Alloy Ring)

(52) The material 11 for ring rolling described above, is ring-rolled by using the ring rolling mill. As the ring rolling mill used in the ring rolling, a mill which has a feature shown in FIG. 10, can be employed. Note that the ring rolling mill may also include guide rolls (centering rolls) and a sizing roll.

(53) In the ring rolling mill shown in FIG. 10, a main roll 21 which can rotate at a predetermined rotational speed, and a mandrel roll 22 which can be rotationally driven around an axis thereof, are arranged so as to face each other on the radially outer peripheral surface 12 and the radially inner peripheral surface 13 of the material 11 for ring rolling. Furthermore, the ring rolling mill also includes two axial rolls 23A, 23B which are arranged so as to face each other on the upper surface and the lower surface of the material 11 for ring rolling in the height direction. If guide rolls which can be rotationally driven, are arranged on both sides of the main roll 21, and the rolling is performed while the outer peripheral portion 14 of the material 11 for ring rolling is supported in order to reduce and suppress misalignment of the material 11 for ring rolling from the center, which may occur during rolling, the rolling can be more stably performed.

(54) The main roll 21 is formed so as to have a columnar shape. This main roll 21 is rotationally driven in a state in which it is brought into contact with the outer peripheral surface 12 of the material 11 for ring rolling so that the material 11 for ring rolling is turned during the ring rolling. For the mandrel roll 22, a cylindrically shaped roll is used. This mandrel roll 22 is configured so as to be freely rotatable around the axis thereof, and is arranged substantially in parallel to the rotational axis of the main roll 21.

(55) The rolling is performed in a state in which the outer peripheral surface of the mandrel roll 22 is in contact with the inner periphery surface 13 of the material 11 for ring rolling. During this rolling, a distance of rolls between the main roll 21 and the mandrel roll 22 is gradually reduced, and as a result, a portion between the radially inner periphery surface 13 and the radially outer peripheral surface 12 of the material 11 for ring rolling is pressed in the thickness direction. The upper and the lower axial rolls 23A, 23B are formed so as to have a conical shape or a truncated conical shape with a vertical angle of 20 degrees to 45 degrees. Furthermore, in order to adjust a dimension of the material 11 for ring rolling in the height direction, the upper and the lower axial rolls 23A, 23B are respectively arranged such that each tip thereof may be oriented to the substantial center of the material 11 for ring rolling. Note that the upper and the lower axial rolls 23A, 23B rotationally drive according to the rotational speed of the material 11 for ring rolling, and alternatively, the upper and the lower axial rolls 23A, 23B may be rotationally driven.

(56) Regarding the process of the rolling, the mandrel roll 22 is inserted through an inner diameter hole of the material 11 for ring rolling, which was heated to a predetermined temperature. The mandrel roll 22 is then gradually moved radially outward such that the interval between the main roll 21 and the mandrel roll 22 may be gradually reduced. After that, when the distance between them became equivalent to the thickness of the material 11 for ring rolling in its initial state, the material 11 for ring rolling is turned due to friction between the surface of the main roll 21 and the outer peripheral surface 12 of the material 11 for ring rolling. In this process, the mandrel roll 22 is rotationally driven so as to follow the rotation of the material 11 for ring rolling.

(57) Subsequently, the interval between the main roll 21 and the mandrel roll 22 is gradually reduced by gradually moving the mandrel roll 22 radially outward (toward the outer periphery). Therefore, the material 11 for ring rolling is pressed in the thickness direction, and the material 11 for ring rolling is plastically deformed along the circumferential direction of the material 11 for ring rolling in a continuous manner. The material 11 for ring rolling used in this process, has the abovedescribed shape provided in the present invention.

Advantageous Effects

(58) Advantageous effects which can be obtained by rolling the material 11 for ring rolling having the shape of the section described above while using the abovedescribed ring rolling mill, will be described below. Hereinbelow, in order to verify action obtained when deforming the portion on the inner peripheral side, which is formed so as to have the tapered shape, the advantageous effects will be described with reference to analysis examples of numerical simulations that were performed by using a calculator. However, in the analysis examples, in order to simplify the numerical calculations, the guide rolls, which may not directly influence the forming, were excluded from subjects of the modeling.

(59) For a condition of rolling in which the outer diameter of the material 11 for ring rolling with the shape of the half section shown in FIG. 2, is increased by 1.2 times thereof, a numerical analysis of ring rolling was practiced by using a three-dimensional rigid-plastic finite element analysis method. Note that an outer diameter of the material 11 for ring rolling was φ600 mm, a maximum thickness of the material 11 for ring rolling was 100 mm, and a thickness of the material 11 for ring rolling on the inner diameter side was 40 mm. While considering a symmetry that a symmetrical surface CL having a shape of a section of the material 11 for ring rolling in a peripheral direction thereof (the symmetrical surface CL which is equivalent to the center line CL viewed from the half section) is a symmetry criterion, displacement of joints which were located on the symmetrical surface CL in the direction of outside of the surface, was constrained, and portions on an upper side of the symmetrical surface CL were used as subjects of the analysis. For the mandrel roll 22 and the axial roll 23A, the condition were set such that they were respectively rotatable around their axes. The diameter of the main roll 21 was φ800 mm, and the main roll 21 was rotatable at a constant speed of 20 revolutions per minute (RPM). Note that the initial heating temperature was set at 980 degrees C. For data of hot flow stress obtained when the alloy equivalent to the 718 alloy was used as the material, data obtained by a compressing test performed at the test temperature ranging from 700 degrees C. to 1100 degrees C., was used.

(60) Each of FIGS. 11(a) to 11(c) shows a changed pattern in the shape of the section in the course of the rolling obtained by the numerical analysis, and distribution of temperature thereof. For comparison, each of FIGS. 11(d) to 11(f) shows a changed pattern in the shape of the section in the course of the rolling performed by using a material for ring rolling having the conventional rectangular section under the same condition as that described above, and distribution of temperature thereof. In FIG. 11, the dot-and-dash line indicated as “CL”, denotes the center line. All of the FIGS. 11(a) to 11(f) show results of simulations for the upper half of the half section which is divided across the center line CL. Note that FIGS. 11(a) to 11(c) and FIGS. 11(d) to 11(f) include diagrams in states of timings at which the mandrel roll 22 and the main roll 21 were at their initial positions while being in contact with the outer peripheral surface 12 and the inner periphery surface 13 of the material 11 for ring rolling (FIGS. 7(a) to 7(d)), diagrams in states of timings at which the outer diameter of the material 11 for ring rolling was increased by 3% (FIGS. 11(b) and 11(e), and diagrams in states of timings at which the outer diameter of the material 11 for ring rolling further was increased by 20% (FIGS. 11(c) and 11(f)).

(61) When seeing the material 11 for ring rolling passing through the main roll 21 and the mandrel roll 22 on a virtual plane which is arranged along the rotational axes of the main roll 21 and the mandrel roll 22 so as to include the rotational axes, in a condition in which the material 11 for ring rolling was pressed in the thickness direction, the dimension thereof in the thickness direction was decreased according to time passage. However, volume of the material 11 for ring rolling itself is constant during the plastic deformation, and as a result, flow of material in the peripheral direction would occur. Furthermore, in the region between the mandrel roll 22 and the main roll 21, the mandrel roll 22 and the main roll 21 are not constrained in the axial direction, and therefore, components of flows in the height direction would also be provided. In the rolling of the material 11 for ring rolling according to the Embodiment of the present invention, the material 11 for ring rolling includes the height reducing portion 17 (having the tapered shape), and therefore, for the flow on the inner side, the region of the tip of the tapered shape to form the free space selectively, is deformed at the initial stage. In this process, the upper and the lower axial rolls 23A, 23B are located on a portion of the maximum thickness, and therefore, the deformation is advanced freely in the height direction in the region on the side of the inner peripheral surface 13.

(62) When seeing the temperature distribution shown in FIGS. 11(a) to 11(c), the rolling was performed in the state in which the temperature was maintained so as to be equal to or less than 1000 degrees C. On the other hand, FIGS. 11(d) to 11(f) show the temperature distribution results obtained when rolling the material with the rectangular section generally used in a conventional manner. In a case of the conventional shape, at the timing at which the outer diameter was increased by 20%, in the inner diameter corner portion, temperature was increased due to the heat of working, and the temperature increased up to approximately 1130 degrees C. In contrast, in cases of rolling the material 11 for ring rolling according to the Embodiment of the present invention, the temperature changed from a start of the rolling to an end thereof was 1000 degrees C. at the maximum, and it can be observed that the rolling was performed within the appropriate temperature range.

(63) Furthermore, FIGS. 12(a) and 12(b) show distribution maps of the distortion obtained by the numerical analysis for the material 11 for ring rolling according to the Embodiment of the present invention and the material for ring rolling with the conventional rectangular section at timing of end of the ring rolling process, respectively. Note that each of FIGS. 12(a) and 12(b) also shows the result of simulation for the upper half of the half section which is divided across the center line CL.

(64) As will be understood from these results, in the case of a conventional technique, heating occurred due to the deformation because of the deformation that had occurred centrally in the inner diameter corner portion. Furthermore, as a result of softening of the material that had occurred due to the heating, value of the distortion was locally equal to or greater than 4. On the other hand, in the case of the Embodiment of the present invention, when seeing the distortion in the inner diameter corner portion, the value of the distortion was approximately 2.5, and therefore, local deformation was reduced so as to be less than that in a conventional technique. Based on these results, it can be understood that deformation within the section is more uniform. When working distortion is provided on the Ni-based superalloy in a high temperature state, coarse grains are recrystallized into fine grains at the initial stage of the process, and as a result, the fine structure is obtained. Note that distortion is generally defined as “((Length after deformation)−(Length before deformation)/(Length before deformation)”. Accordingly, the following conventional problem can be solved, that is to say, in the conventional problem, coarsening of grains occurs in portions, such as the inner diameter corner portion with excessively high temperatures, so that the distribution of distortion becomes non-uniform due to local deformation, and as a result, the structure becomes non-uniform.

(65) Accordingly, even if a ring is formed in the same target shape as that targeted by the conventional technique, the shape according to the Embodiment of the present invention is applied to the material for ring rolling so that heating which occurs during rolling, can be suppressed, recrystallization for refining of the grains is advanced in a state in which growth of the crystal grains of the Ni-based superalloy is suppressed, and therefore, a ring with an excellent quality can be shaped by rolling. As described above, the shape of the material 11 for ring rolling according to the Embodiment of the present invention, includes a space which is formed between the height reducing portion 17 (having the tapered shape) and the maximum height portion of the material 11 for ring rolling, and plastic deformation is advanced such that the material gradually flows into the region in the course of the pressing. Therefore, local concentration of deformation is prevented, and deformation of the entire ring can be made uniform. As a result, occurrence of abnormally high heating is prevented, the heat load applied to the axial roll can be reduced to a low level, and therefore, life of the axial roll can be enhanced.

(66) In contrast, in a case in which the conventional shape of a material for rolling is used, if the corner portion is filled with the material before completion of the rolling, the portion of the material in locations close to the corner portion is compressed between the mandrel roll 22 and the main roll 21 in the thickness direction, and therefore, the material which cannot be rolled in an appropriate direction flows in the height direction. On the other hand, the portions in the locations close to the corner portion is compressed between the upper and the lower axial rolls 23A and 23B in the height direction which is opposite to the above direction of flow of the material, and therefore, the material which cannot be rolled in an appropriate direction flows in the thickness direction. Accordingly, the deformation occurs repeatedly for each and every rotation, and as a result, heating occurs due to the deformation. In particular, since heat conductivity of Ni-based superalloys is low, once heating occurs, it takes time for temperature to decrease, and as a result, the temperature rises due to the repeated local deformation which occurs during the ring rolling. Therefore, the temperature of the material reaches 1050 degrees C. within a temperature region in which the crystal grains are coarsened, and therefore, the material may include portions with poor strength characteristics after the rolling is finished.

(67) Examples of means for preventing this problem include means, such as water cooling, provision of extra shaped portions, reduction of the rolling speed, and the like. However, in the case of water cooling, it is significantly difficult to manage the temperature according to the progress of the rolling process. If any extra shaped portions are provided, and the margin for cutting off the extra shaped portions is provided, the material production yield may degrade, and required rolling capacity may be increased. If the rolling speed is reduced to suppress occurrence of heating in the corner portion, time taken until completion of the rolling may become longer, and therefore, this causes decrease of temperature in the other portions.

(68) For the material 11 for ring rolling according to the Embodiment of the present invention, the material is formed by using a preliminary process equivalent to that of the conventional technique. Furthermore, for the material 11 for ring rolling, a columnar billet is forged by upset hot forging, the center thereof is punched by using punching dies, and then, where necessary, the material is cut by machining so as to have the shape according to the Embodiment of the present invention. Therefore, the shape of the material for ring rolling described above can be easily obtained. Note that it is more suitable if a fillet portion (curved portion) is provided in connecting portions on each side edge thereof, because local contact with the axial roll can be prevented, and abrasion of the axial roll can be suppressed.

EXAMPLES

(69) For an alloy equivalent to a 718 alloy used for a disk for a gas turbine of a diameter of Φ1000 mm or larger, the forming method of the material for ring rolling shown in FIG. 1, was applied to form the material 11 for ring rolling shown in FIG. 2. A hot forging temperature for the alloy equivalent to the 718 alloy was set at 920 degrees C. For the shape of the dies used in the Example, the upper and the lower dies shown in FIG. 6 were used. The angle of the convex portion with the truncated conical shape (θ) was 32 degrees.

(70) The dimensions of the material 11 for ring rolling were set so as to be the values shown in Table 1. Specifically, the outer peripheral portion 14 of the material 11 for ring rolling in contact with the main roll was shaped so as to have the curved surface shape tapered toward the outer periphery. The shape of the half section of the material 11 for ring rolling included the height reducing portion 17 formed so as to reduce the height from the center line CL which divides the half section into halves in the height direction, toward the inner peripheral surface 13 which is in contact with the mandrel roll. Furthermore, the shape of the half section of the material 11 for ring rolling was shaped with substantially linear symmetry so as to define the center line CL as the symmetrical axis. The center of gravity G on the half section of the material 11 for ring rolling was located so as to be closer to the side of the main roll than the center CP of the material 11 for ring rolling in the thickness direction, i.e., was located so as to be closer to the side of the outer peripheral surface 12.

(71) TABLE-US-00001 TABLE 1 Dimensions of material for ring rolling Outer diameter 800 mm Inner diameter 404 mm Thickness 196 mm Maximum height (H1) 200 mm Height of inner peripheral  48 mm surface (Hin) Length of height reducing 126 mm portion Length of linear portion  20 mm

(72) For the material 11 for ring rolling, ring rolling was performed by using the ring rolling mill shown in FIG. 10. The ring rolling mill used in this test, was provided with the guide rolls and the measuring roll. The material 11 for ring rolling was heated to 990 degrees C. before starting the ring rolling. During the ring rolling, similarly to the results of simulations described above, the deformation was advanced freely in the height direction in the region on the side of the inner peripheral surface 13, and it was not observed that heating at excessively high temperature occurs abnormally. Accordingly, the number of times of heating occurred was as little as twice, and the production time could be shortened. In addition, since the linear portion (flat portion) 15 including the end surface 16 in the height direction, which extended substantially so as to be linear, was provided between the outer peripheral portion 14 and the height reducing portion 17, the ring rolling could be stably performed when the material was pressed with the axial roll. By performing the ring rolling in this manner, the material 11 for ring rolling including a rectangular shape, which had an outer diameter of 1141 mm, an inner diameter of 933 mm, a thickness of 104 mm, and a height of 189 mm, could be obtained.

(73) The material 11 for ring rolling was subjected to visual inspection of its appearance, and then, it was inspected for defects such as cracking, chipping, and these were not found for the material 11 for ring rolling, and the material 11 for ring rolling was formed in a substantially true-circular shape.

(74) Test pieces for observation of the metal structure were sampled from the material 11 for ring rolling. The sampling portions were the upper portion, the inner diameter portion, the center portion, the outer diameter portion, and the lower portion of the material 11 for ring rolling (the ring mill rolling material). The metal structure of the material 11 for ring rolling was observed by using an optical microscope, and furthermore, the grain size number was measured. The measurement of the grain size was practiced according to the measurement method provided by ASTM-E112. The results of the measurement of the grain size are shown in Table 2, and photographs of the metal structure are shown in FIG. 13.

(75) TABLE-US-00002 TABLE 2 Observed portions Average grain size number Upper portion 11 Inner diameter portion 11 Center portion 10.5 Outer diameter portion 11 Lower portion 10

(76) According to the results of the observation of the metal structure and the results of measurement of the average grain size on the section, it can be understood that the crystal grains were uniform and fine in the material for ring rolling which was produced by using the material 11 for ring rolling according to the Embodiment of the present invention. Accordingly, it was verified that uniform and optimum distortion was applied onto the entire surface of the material 11 for ring rolling, and this material 11 for ring rolling was suitable to be employed as a material of a rotational component which was used for a high temperature portion of a gas turbine.

REFERENCE SIGNS LIST

(77) 1 Ni-based superalloy for ring rolling 2 Upper die (upper molding die) 3 Lower die (lower molding die) 4 Thin portion 11 Material for ring rolling 12 Outer peripheral surface 12a End portion 12b Upper portion 12c Lower portion 12d Intermediate portion 13 Inner peripheral surface 13a End portion 14 Outer peripheral portion 15 Linear portion 16 End surface 17 Height reducing portion 18 Slanted surface 21 Main roll 22 Mandrel roll 23A Upper axial roll 23B Lower axial roll CA Central axis CP Center CL Center line Hin Height of inner peripheral surface H1 Maximum height of material for ring rolling θin Angle