Various problems often occur in the production of automobile forgings, such as hot cracks, excessive deformation or unqualified size, cold cracks, indentation or folding, and insufficient billet or excessive waste. These problems have brought a lot of trouble to automobile forging enterprises. This article will show you how to solve these common problems.
First, hot crack
Thermal cracking is caused by local deformation and stress concentration due to internal differentiation of the material. In order to avoid the generation of thermal cracks, we can adopt the following measures:
- Select the appropriate material to improve its heat resistance;
- Reasonable design of process parameters to ensure that the temperature and stress of the material reach the appropriate state;
- Properly preheat the material so that the temperature reaches a certain uniformity.
- Excessive deformation or unqualified size
Deformation problems caused by forging may lead to the size of the material does not meet the requirements, thus affecting the quality of the product. To avoid this, we can use the following methods: - Design a reasonable mold: a reasonable mold can reduce deformation. If you need to manufacture very fine parts, it is best to use high-precision equipment such as CNC machine tools to ensure the accuracy of mold manufacturing and forging;
- Control the amount of deformation in the forging process: adopt reasonable design parameters, appropriate process operation and ensure that the hammer and mold assembly are relatively independent to avoid affecting each other, so as to achieve the purpose of reducing deformation;
- Carry out reasonable follow-up processing operations to make the size meet the specifications.
Three, cold crack
Cold cracks are usually caused by defects in the forging under the action of stress. In order to avoid the occurrence of cold cracks, we can adopt the following measures:
- Start with material selection, avoid raw materials with inherent defects,
- Design a reasonable process flow, and fully preheat to maintain temperature and uniformity;
- Adequate heat treatment to eliminate residual stresses and defects in forgings.
- Indentation or folding
Indentation or folding may affect the surface quality of the forging. To solve this problem, we need: - Use suitable surface treatment methods, such as sandblasting, pickling, grinding, etc.
- Optimize the process control, reasonably adjust the hammer force, reduce the surface marks;
- Reasonable selection of hammer, mold assembly, reduce the local force on the surface of the forging.
- Insufficient or excessive waste of blanks
Optimizing the use of materials can reduce costs and improve efficiency, thereby increasing the profitability of enterprises. We can use the following methods: - Determine the demand for materials in appropriate proportions;
- Strictly comply with product design requirements to minimize waste;
- Strengthen the contact with material suppliers, and save costs as much as possible under the conditions of time and quality.
To sum up, the solutions to common problems in the production of automobile forgings include both technical improvement and optimization, and standardization and excellence at the management level. For forging enterprises, solving common problems is not terrible, it is difficult to persevere to continue to improve, enhance the core quality and overall competitiveness of enterprises.
