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English
Forging technology is a processing method that applies external force to cause plastic deformation of metal materials in a solid state, thereby obtaining the desired shape, size, and properties. Improving the efficiency and product quality of forging processes can be approached from the following aspects:
1. Material selection and pretreatment
Material optimization: Select metal materials suitable for forging, such as carbon steel, alloy steel, aluminum alloy, etc., to ensure good plasticity and forging performance.
Pre treatment of billets: Uniform heating of billets to avoid internal stress concentration and improve the plastic deformation ability during forging.
2. Heating process control
Accurate temperature control: Based on the forging temperature range of different materials (such as carbon steel usually between 1100-1250 ° C), advanced heating equipment (such as induction heating furnaces) is used to ensure uniform temperature.
Avoid overheating or overburning: Excessive temperature can cause coarse grains or material burning, affecting performance.
3. Forging equipment and mold optimization
Equipment upgrade: Adopting high-precision forging presses (such as hydraulic presses, screw presses) or forging equipment to improve forming efficiency and consistency.
Mold design: Optimize mold structure, reduce burrs and material waste, and improve mold life (such as using hard alloy or surface coating technology).
4. Optimization of process parameters
Deformation rate control: Reasonably control the forging speed to avoid cracking caused by too fast or affecting efficiency caused by too slow.
Multi pass forging: For complex parts, multiple passes of deformation are used to gradually approach the shape and reduce internal defects.
5. Quality control and testing
Real time monitoring: using infrared temperature measurement, ultrasonic detection and other methods to monitor the temperature and internal defects during the forging process.
Subsequent heat treatment: Refining the grain size and improving the mechanical properties of the forging through processes such as normalizing, quenching, and tempering.
6. Automation and Intelligence
Robot assisted: Utilizing robotic arms to achieve automated operations such as billet handling and mold lubrication, reducing manual intervention.
Data driven optimization: Combining big data and AI analysis of historical process data, dynamically adjusting parameters to improve yield.
7. Green forging technology
Energy saving heating: using regenerative combustion technology or electric heating to reduce energy consumption.
Waste recycling: Recycling and reusing forging burrs and waste materials to reduce material costs.
8. Personnel training and standardization
Skill enhancement: Regularly train operators to become familiar with the operating standards of new materials and equipment.
Standardized operation: Establish a comprehensive process specification (such as ISO 9001) to ensure consistency of each batch of products.
Application Cases
Automotive crankshaft forging: using quasi dense forging and waste heat quenching process to reduce subsequent processing steps and improve strength.
Aviation titanium alloy forgings: By isothermal forging (slow deformation+constant temperature mold) to avoid cold mold effect and obtain uniform structure.
Through the above measures, the efficiency, accuracy, and product performance of forging processes can be significantly improved, while reducing costs and scrap rates. In actual improvement, targeted optimization should be carried out based on specific material, equipment, and product requirements.
