Barrel forgings are used in many industries, from mechanical parts to structural supports, and are widely used in various types of equipment and facilities. In order to ensure the quality and performance of these
forgings, every part of the forging process needs to be controlled and optimized. From the selection of raw materials to the quality control of the final product, each step directly affects the final result of the forging. This paper will introduce the forging process of barrel forgings in detail, including raw material selection, counting and cutting, heating, deformation force calculation and equipment selection, lubrication method and lubricant selection, mold design, forging operation and quality control, etc., in order to provide comprehensive reference and guidance for relevant industry personnel.
Forging materials include steel, superalloy, aluminum, magnesium, titanium, copper, etc. When selecting materials, it is necessary to consider its performance, source and use. Steel is suitable for most forging applications, superalloys for high-temperature environments, aluminum, magnesium, and titanium for lightweight needs, and copper for electrical and heat exchanger components. Choosing the right material is crucial to the quality of the forging, and the best choice needs to be made according to the process requirements.
Counting is the process of calculating the amount of raw materials needed to reduce waste and optimize material utilization. Blanking is the step of cutting the raw material to the appropriate size, and it is necessary to consider leaving enough margin to cope with the process adjustment, while the quality of the blanking end face affects the effect of the final forging. Reasonable cutting can reduce scrap rate and die wear.
The purpose of heating is to reduce the deformation force and improve the plasticity of the metal. The heating methods include flame furnace heating and electric induction heating. Flame furnace heating cost is low, but heating time is long, easy oxidation and decarbonization; Electric induction heating heating is rapid and less oxidation, but the adaptability to the material is poor. Controlling the heating temperature has great influence on the microstructure and properties of forging parts, so it is necessary to precisely control the initial forging temperature and the final forging temperature.
Deformation force calculations help select the right equipment and design the mold. Common calculation methods include principal stress method, slip line method, upper limit method and finite element method. The principal stress method is used to calculate the total pressure and stress distribution. The slip line method is suitable for the plane strain problem. The upper limit method provides overestimation of load and predicts the shape change of the workpiece; The finite element method can describe the external load and the internal stress and strain distribution in detail, and the calculation accuracy is high but the time is long. In recent years, joint analysis methods, such as the combination of upper bound method and finite element method, have improved the computational efficiency and accuracy.
Lubrication reduces friction, saves energy and increases mold life. Lubricants are selected according to the forging process and material, for example: glass lubricants are commonly used in superalloy and titanium alloy forging, water-based graphite lubricants are used in steel hot forging, and phosphate or oxalate treatment is required for cold forging to enhance wear resistance. Different lubricants are suitable for different forging environments and materials, choosing the right lubricant is the key to improve the quality of forging.
Mold design needs to be determined according to the shape of the forged parts, material characteristics and deformation force. The die must withstand the high temperatures and pressures of the forging process and ensure that the predetermined shape of the forging is accurately formed. Mold materials should have wear and high temperature resistance to extend service life and reduce problems in production.
The forging operation involves placing a heated material into a die and applying an external force through a hammer or press. During the operation, it is necessary to monitor the status of the mold and equipment, control the deformation speed and pressure, and ensure that the size and shape of the forged parts meet the requirements. Precise operation helps to obtain the best forging results and product quality.
After forging is complete, a quality control check is carried out, including the inspection of size, surface quality and internal organization. Common testing methods include visual inspection, dimensional measurement, ultrasonic testing, etc., to ensure that the forging meets the design specifications and technical standards. Good quality control can ensure the reliability and performance of forgings in actual use.
Through the detailed analysis and description of the forging process of cylinder forgings, it can be seen that accurate operation and control is the key to ensure product quality. Every link, from the selection of materials to the final quality inspection, requires rigorous management and scientific methods. Mastering these processes and technologies not only improves production efficiency, but also improves the performance and reliability of the final product. It is hoped that the in-depth discussion provided in this paper can provide valuable reference for professionals in related industries in actual operation, and promote the continuous progress and optimization of forging technology.
