Forged flanges are an important connecting component that is widely used in various industrial fields. During the production process, some problems often occur, such as heat treatment of materials, quality of billets, and processing of semi-finished products. To effectively solve these issues, it is essential to strengthen process management, quality control, and equipment maintenance.
- Process-related problems In the production process of forged flanges, problems related to material heat treatment, billet quality, and semi-finished product processing frequently arise. For instance, insufficient temperature control of the steel billet might lead to deformation, while improper parameter settings during heat treatment may cause a reduction in material properties. To solve these problems, companies should have professional and technical personnel to manage the process, accurately control the process parameters, and ensure effective control and implementation of every step.
- Quality Control Issues Quality control plays a vital role in the production of forged flanges. Without adequate inspection and control measures, it’s difficult to ensure product quality. Surface quality and dimensional accuracy control require careful inspection and control, in addition to strict chemical composition testing and mechanical performance testing.
3.Equipment Maintenance Problems Maintenance and repair of equipment are also critical in the production process of forged flanges. Failure of equipment can significantly cause production delays which might result in huge losses for the company. Therefore, companies should maintain their equipment and conduct inspections regularly to ensure smooth operation.
In an actual case, a large enterprise experienced significant losses due to quality problems during semi-finished product processing. Studies revealed that these losses were mainly caused by the quality of the billets and heat treatment processes. To solve the problem, the company employed the following solutions:
- Strengthened the quality inspection of billets, selected suitable steel billets, and established more scientific specifications for heating and forming.
- Optimized the heat treatment process flow, established more stringent operating procedures and parameter settings, and ensured accurate control at every stage.
- Established an integrated quality control system to ensure that each product passed chemical composition testing and mechanical performance testing.
Through the above solutions, the company effectively resolved production problems resulting in the overall increase of product quality and efficiency.
