Hydropower forging is an important part of hydropower equipment, its quality and performance directly affect the operation efficiency and safety of hydropower equipment. However, in the production process of hydropower forgings, due to various reasons, there will inevitably be some defects. These defects not only affect the quality and performance of the product, but can also lead to accidents in the production process. Therefore, it is of great significance to analyze the defects of hydropower forging production and adopt corresponding quality control strategies for improving product quality and production efficiency. This paper will introduce the relevant technology in the production of hydropower forgings from two aspects of defect analysis and quality control strategy.
Defect analysis of hydropower forging production
In the production process of hydropower forgings, the common defect types mainly include crack, folding, inclusion, porosity and so on. The causes and hazards of these defects are as follows:
Cracks: Cracks are caused by excessive stress or strain on the material during forging. The existence of cracks will seriously affect the strength and toughness of the workpiece, and even lead to the fracture of the workpiece during use.
Folding: Folding is caused by excessive local deformation of the material during the forging process. The existence of folding will worsen the surface quality of the workpiece and affect the fatigue strength and wear resistance of the workpiece.
Inclusion: Inclusion is due to the presence of impurities in the raw material or mixed with foreign bodies during the forging process. The presence of inclusions will affect the strength and toughness of the workpiece, and even lead to fatigue fracture of the workpiece during use.
Pores: Pores are formed because the gas is not discharged in time during the forging process. The existence of pores will affect the density and strength of the workpiece, and even lead to corrosion and fatigue fracture of the workpiece during use.
In view of the above defects, the following prevention and improvement measures can be taken: optimize the forging process to reduce the stress concentration and deformation of the workpiece; Control the quality of raw materials to reduce the mixing of impurities and foreign bodies; Improve the forging equipment, improve the gas discharge efficiency in the forging process.
Quality control strategy of hydropower forgings production
In order to improve the quality and performance of hydropower forgings, the following quality control strategies need to be adopted:
Quality control in the design stage: in the design stage, the structure and process of hydropower forgings should be fully analyzed and optimized to reduce the stress concentration and deformation of the workpiece in the forging process, and avoid the generation of defects such as cracks and folding.
Process control in the manufacturing process: in the manufacturing process, each process should be strictly controlled and inspected to ensure that the quality and performance of each process meet the requirements. At the same time, advanced forging equipment and process methods should be used to improve the density and strength of the workpiece and reduce the generation of defects such as pores.
Finished product inspection after completion: After completion, hydropower forgings should be comprehensively inspected and tested to ensure that the quality and performance of the product meet the requirements. For defective products, they should be repaired or scrapped in time to avoid entering the market and affecting the safety of use.
Quality traceability and continuous improvement: Establish a sound quality traceability system and continuous improvement mechanism, timely analysis and treatment of quality problems in the production process, and constantly improve product quality and production efficiency. At the same time, communication and collaboration with suppliers and customers should be strengthened to jointly promote the quality of hydropower forgings.
Taking the production of hydropower forgings in a hydropower station as an example, there are a large number of cracks and folding defects in the production process. Through the analysis and optimization of the production process, it is found that these defects are mainly due to the unreasonable forging process and the quality control of raw materials is not strict. To solve these problems, enterprises have taken measures to optimize the forging process and control the quality of raw materials, which effectively reduce the occurrence of cracks and folding defects. At the same time, the company has strengthened the process control in the manufacturing process and the finished product inspection after completion to ensure that the quality and performance of the products meet the requirements. In the end, the product quality of the enterprise has been greatly improved, and won the trust of customers and market reputation.
The defect analysis and quality control strategy of hydropower forging production are the key links to improve product quality and production efficiency. By analyzing and preventing the common defects, corresponding quality control strategies can be adopted to reduce or avoid the occurrence of these defects. In the future, with the continuous development of science and technology and the intensification of market competition, the defect analysis and quality control 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.
