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English
The forging process achieves effective metal forming through plastic deformation, which not only improves material properties such as strength and toughness, but also produces quasi dense parts with complex shapes. The following are the key technologies, advantages, and typical applications of forging technology to achieve effective forming.
1、 The core advantages of forging technology (compared to casting and machining)
Comparative forging process advantages Typical application scenarios
Organizational density eliminates pores and shrinkage porosity, and grain refinement (strength increases by 20-30%) for aircraft engine blades and automotive crankshafts
Mechanical properties: Continuous fiber streamline, fatigue life increased by 50% for high-speed rail axles and wind turbine spindles
Material utilization rate near net forming (material waste<10%, machining="">30%) for gears and connecting rods
Production efficiency: High speed forging (30-60 pieces per minute), standard parts (bolts, nuts)
2、 The key technology for effective forging forming
1. Quasi dense forging (closed forging)
Process features: Closed mold cavity, controlled metal flow, no burrs
Accuracy: up to IT7-IT8 level (± 0.05mm), reducing subsequent processing
Case: Automotive gearbox gears (tooth profile directly forged, eliminating the hobbing process)
2. Multi directional forging
Principle: By applying compressive stress in multiple directions, coarse grains are broken and uniformity is improved
Effect:
The grain size of titanium alloy is refined from 50 μ m to 5 μ m
60% reduction in anisotropy (suitable for aviation load-bearing components)
3. Isothermal forging
Condition: Mold and billet at the same temperature (titanium alloy: 900-950 ℃), low-speed deformation
Advantages:
One time molding of complex thin-walled components (such as aircraft engine casings)
The residual stress is very low (only 30% of conventional forging)
4. Incremental Forging
Application: Local continuous deformation, suitable for large-sized parts (such as ship crankshafts)
Advantage: Equipment tonnage requirement reduced by 50% (gradually formed, not fully loaded)
3、 Typical effective molding cases
1. Automotive crankshaft (42CrMo steel)
Process: Hot forging+residual heat quenching
Effect:
Tensile strength ≥ 900MPa (40% higher than cast crankshaft)
Production cycle time: 45 seconds per piece (fully automated production line)
2. Aircraft titanium alloy frame (Ti-6Al-4V)
Process: Isothermal Superplastic Forging
Effect:
Weight loss of 30% (compared to traditional structures)
Fatigue life>10 cycles (meets civil aviation airworthiness standards)
3. Aluminum alloy wheels (A356)
Process: Liquid forging (squeeze casting)
Advantages:
Pore rate<0.1% (traditional casting is 2-5%)
Surface smoothness Ra ≤ 3.2 μ m (without rough machining)
4、 The future trend of forging effective forming
Composite process:
3D printing+forging: printing near net shape blanks, quasi dense forging forming (material utilization rate>95%)
Semi solid forging: Metal is formed in a solid-liquid mixture state (reducing energy consumption by 40%)
Intelligent control:
AI based adaptive optimization of forging parameters (real-time adjustment of temperature and speed)
Digital Twin simulates deformation process and predicts defects
Green forging:
Cold forging/warm forging replaces hot forging (reduces heating energy consumption)
Waste recycling (re forging of waste mold steel)
Summary: The core logic of forging effective forming
Material optimization: fine grain strengthening, fiber streamline design
Process innovation: isothermal/multi-directional/incremental forging breaks through traditional limitations
Digital empowerment: simulation+intelligent control improves success rate
The forging process has become an indispensable core technology in manufacturing through continuous upgrading of "quasi densification, lightweighting, and intelligence"!
