With the rapid development of wind power industry, the production process optimization and cost control of wind power forgings are particularly important. This paper will start from two aspects of wind power forging production process optimization and cost control, aiming at improving the quality and production efficiency of wind power forging, while reducing production costs.
First, wind power forging production process optimization
The production process is introduced
The production process of wind power forging mainly includes the following links:
(1) Smelting: smelting raw materials into molten steel suitable for forging through the smelting process;
(2) Forging: pour the molten steel into the mold, and forge through the forging hammer or press to form the required forging shape;
(3) Heat treatment: through the process of heating and cooling, the internal microstructure of the forging is changed to achieve the required mechanical properties;
(4) Machining: cutting, drilling, milling and other processing of forgings to meet the requirements of drawings;
(5) Testing: Quality testing of forgings to ensure that they meet standard requirements.
The need to optimize the production process flow
There are some problems in the traditional production process of wind power forgings, such as low production efficiency, waste of raw materials, and unstable product quality. Therefore, it is necessary to optimize the production process:
(1) Improve production efficiency, shorten production cycle and reduce production costs;
(2) Reduce waste of raw materials and reduce costs;
(3) Improve product quality and stability, reduce scrap rate.
Specific measures to optimize the production process
In view of the problems existing in the traditional wind power forging production process, this paper proposes the following optimization measures:
(1) The use of new smelting technology, such as vacuum smelting, electroslag remelting, etc., to improve the purity of raw materials, reduce the content of impurities, improve the mechanical properties of forgings;
(2) Adopt precision forging technology, such as high-speed hammer forging, hot die forging, etc., to improve forging accuracy and production efficiency;
(3) Optimize the heat treatment process parameters, use advanced heating and cooling control technology to improve the transformation effect of the internal microstructure of the forging, so as to improve the mechanical properties of the forging;
(4) The introduction of automation and intelligent machining equipment to improve processing accuracy and efficiency;
(5) Strengthen the quality testing in the production process, and adopt advanced non-destructive testing technology, such as ultrasonic testing, X-ray testing, etc., to improve the detection accuracy and efficiency.
The effect after optimizing the production process
Through the implementation of the above optimization measures, the production process of wind power forging will be improved as follows:
(1) The production efficiency is increased by 30% and the production cost is reduced;
(2) The waste of raw materials is reduced by 20%, reducing the cost;
(3) Product quality and stability are improved, and the rejection rate is reduced by 10%.
Two, wind power forging cost control
The importance of cost control
In the fierce market competition in the wind power industry, the cost control of wind power forgings is of great significance to the survival and development of enterprises. Effective cost control can help enterprises reduce costs, improve market competitiveness, but also can enhance the enterprise’s anti-risk ability.
Difficulty of cost control
There are the following difficulties in the cost control of wind power forging:
(1) Rising prices of raw materials, resulting in increased costs;
(2) Increases in labor costs and energy costs;
(3) The production process is complex, many links, difficult to achieve comprehensive control;
(4) High scrap rate, resulting in increased costs.
Specific measures of cost control
In view of the above difficulties, this paper puts forward the following cost control measures:
(1) Strengthen raw material procurement management, adopt centralized procurement, long-term contracts and other ways to stabilize raw material prices and reduce procurement costs;
(2) The introduction of automation and intelligent equipment to reduce labor costs and energy consumption;
(3) Establish a comprehensive cost control system, the cost control throughout the whole process of production, including raw materials, labor, energy, machining and other links;
(4) Strengthen quality testing and reduce the rejection rate. Through the implementation of the above measures, the following cost control effects can be achieved: the total cost is reduced by 15%, while the specific costs of raw materials, labor and energy are also effectively controlled.
