How to reduce energy consumption in the production of aluminum forgings? Please use a practical production case to illustrate and write an article in Chinese and translate it into English.
The production of aluminum forgings is a high-energy-consuming manufacturing process, in which a large part of the energy is consumed in the heating and insulation steps of the aluminum forging machine. Therefore, reducing energy consumption is a problem that every aluminum forging production enterprise needs to face.
Firstly, the energy consumption can be reduced by changing the material ratio and blank shape of the forging production, such as properly setting the content and sales ratio of various elements in the aluminum alloy, controlling the pre-treatment of aluminum ingots and avoiding corner leftovers during blank shaping to reduce heating energy consumption.
Secondly, the utilization of the aluminum forging equipment can be optimized to improve its efficiency. In the steps of heating, insulation, blank loading, and cooling, precise adjustment of heating time and temperature, reasonable configuration of extrusion machine molds to increase first-time forming rate, and to improve the shaping quality of products, in order to achieve energy-saving purposes.
Finally, strengthening management and technological innovation to improve the energy efficiency of the entire production process. Develop a scientific production plan, coordinate production progress and machine idle status, strengthen equipment maintenance and repair to ensure that the equipment operates in the best working condition. Actively carry out technological innovation, adopt advanced measuring and testing equipment, research and development of new technologies such as heat exchange and energy saving, to improve product processing performance and production efficiency.
Case analysis: A certain aluminum forging enterprise has successfully implemented multiple measures in optimizing energy management, such as installing temperature measuring instruments and precisely controlling the heating time and temperature in the heating step, reducing rework rates and improving energy efficiency significantly. At the same time, optimizing equipment performance and maintenance systems, improving durability and stability, and reducing equipment maintenance times have earned greater economic benefits for the enterprise.
