Hydropower forging is an important part of hydropower equipment, its quality and performance directly affect the operation efficiency and safety of hydropower equipment. In the production process of hydropower forgings, residual stress will inevitably occur due to various reasons. These residual stresses not only affect the quality and performance of the product, but can also lead to accidents during the production process. Therefore, it is of great significance to analyze the residual stress in the production of hydropower forgings and take corresponding measures to eliminate it for improving product quality and production efficiency. This paper will introduce the relevant technology in the production of hydropower forgings from two aspects of residual stress analysis and removal measures.
In the production process of hydropower forgings, the causes of residual stress mainly include the following aspects:
Thermal stress generated during heat treatment: In the heat treatment process, due to the existence of internal temperature gradient of the workpiece, thermal stress will be generated inside the workpiece. These thermal stresses will be converted into residual stresses after the workpiece is cooled.
Plastic deformation stress generated during forging: In the forging process, plastic deformation stress will be generated due to the plastic deformation of the workpiece. These plastic deformation stresses will be transformed into residual stresses after the workpiece is cooled.
Mechanical stress generated during processing: In the process of processing, because the workpiece is subjected to the cutting force, mechanical stress will be generated. These mechanical stresses are converted into residual stresses after the workpiece is cooled.
Through the analysis of the residual stress produced in the production process of hydropower forging, it can be found that the residual stress is mainly distributed on the surface and inside of the workpiece. Among them, the surface residual stress is mainly caused by the action of cutting force on the workpiece surface. The internal residual stress is mainly caused by the internal temperature gradient and plastic deformation of the workpiece. The existence of these residual stresses will adversely affect the dimensional stability, fatigue strength and corrosion resistance of the workpiece.
In order to eliminate residual stress in the production of hydropower forgings, the following measures can be taken:
Optimize the heat treatment process: By optimizing the heat treatment process, the existence of the internal temperature gradient of the workpiece can be reduced and the generation of thermal stress can be reduced. For example, the use of isothermal quenching process can reduce the temperature gradient inside the workpiece and reduce the generation of thermal stress.
Improved forging process: By improving the forging process, the plastic deformation stress inside the workpiece can be reduced. For example, the use of multiple forging processes can reduce the plastic deformation stress inside the workpiece and improve the dimensional stability of the workpiece.
Optimization of processing technology: By optimizing the processing technology, the mechanical stress on the workpiece surface can be reduced. For example, the use of precision cutting technology can reduce the mechanical stress on the surface of the workpiece and improve the surface quality of the workpiece.
Using vibration aging treatment: Vibration aging treatment is an effective method to eliminate residual stress. By using vibration aging treatment, the residual stress inside the workpiece can be eliminated by using the alternating stress generated by vibration. This method has the advantages of short processing time and good effect.
The method of combining heat treatment with mechanical treatment: The method of combining heat treatment with mechanical treatment can eliminate residual stress more effectively. For example, heat treatment at high temperatures and then mechanical treatment at room temperature can effectively eliminate residual stress inside the workpiece.
The analysis and elimination of residual stress in the production of hydropower forgings is an important means to improve product quality and production efficiency. By analyzing the residual stress and taking corresponding measures to eliminate it, the optimal allocation and utilization of resources can be realized, and the quality and performance of products can be improved. In the future, with the continuous development of science and technology and the intensification of market competition, the residual stress analysis and elimination measures of hydropower forging production will become an important development direction of the manufacturing industry. Therefore, enterprises need to continuously strengthen technological innovation and equipment update, adopt more environmentally friendly and advanced manufacturing processes and equipment to improve resource utilization efficiency and reduce environmental pollution; At the same time, it is also necessary to strengthen the construction of corporate management and social responsibility to lay a solid foundation for the sustainable development of enterprises and social contributions. Only in this way can the green manufacturing and sustainable development of hydropower forging production be achieved to contribute to the long-term development of enterprises and the sustainable development of society.
