Analysis of the failure and investigation of the accident causes of metallurgical machinery hydraulic cylinder piston forgings is conducted to identify the root causes leading to the failure of piston forgings and take appropriate measures to prevent similar accidents from recurring. The following are the common steps and methods for failure analysis and accident cause investigation:
- Record the damage: Record detailed information about the damaged piston forgings, including the specific time, location, operating conditions, and working load of the accident. Also, take photographs or create sectional drawings of the damaged area for subsequent analysis.
- Assessment of failure modes: Analyze the failure modes of the piston forgings, such as fracture, fatigue, deformation, corrosion, etc. Based on the characteristics of the failure, determine whether it was caused by external impact, overload, fatigue cycling, or other factors.
- Material performance testing: Conduct material performance testing on the damaged piston forgings, including hardness testing, microscopic examination of the microstructure, chemical composition analysis, etc., to determine whether the materials meet specification requirements and whether there are any defects or abnormalities.
- Analysis of process parameters: Analyze the manufacturing process parameters of the piston forgings, including forging temperature, forging pressure, cooling method, etc. Check whether the process parameters are reasonable and whether there are any anomalies or changes that could indicate problems during the manufacturing process.
- Evaluation of operating conditions: Evaluate the operating conditions of the piston forgings, including the working environment, temperature, lubrication condition, etc. Analyze the forces and stresses that the piston forgings are subjected to under actual working conditions, and determine whether there are overload or excessive load situations.
- Design evaluation: Evaluate the design of the piston forgings, including geometric shape, dimensional size, material selection, etc. Examine whether the design is reasonable and whether there are stress concentration or weak areas.
- Comprehensive analysis: Based on the above testing and evaluation results, conduct a comprehensive analysis of the failure causes of the piston forgings. Possible causes may include material defects, design flaws, process issues, improper usage, etc.
Through the analysis of failure and investigation of accident causes, the root causes leading to the failure of piston forgings can be identified, and corresponding measures can be taken for improvement and prevention. In daily work, it is also important to regularly inspect and maintain piston forgings to ensure their normal operation and safe use.
