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, material deformation is a common problem, it will not only affect the quality and performance of the product, but also may lead to accidents in the production process. Therefore, it is of great significance to study the material deformation and control technology of hydropower forging production. This paper will introduce the material deformation and control technology in the production of hydropower forgings from three aspects of the cause, influence and control technology of material deformation.
Causes and effects of material deformation
In the process of hydroelectricity forging, the main causes of material deformation include temperature, stress, chemical composition and organizational structure. These factors act in different ways, but the influence on the deformation of the material is significant. For example, too high temperature will lead to softening of the material, too much stress will cause plastic deformation of the material, and the non-uniformity of chemical composition and organizational structure may also lead to deformation of the material.
Material deformation has a negative effect on the quality and performance of hydroelectric forgings. First of all, deformation may lead to the size and shape of the workpiece does not meet the requirements, affecting assembly and use. Secondly, deformation may change the internal structure and properties of the material, reducing the strength and toughness of the workpiece. Finally, deformation may also cause surface defects of the workpiece, such as cracks, folding, etc., seriously affecting the quality and life of the workpiece.
In order to control material deformation in the production of hydropower forgings, the following measures can be taken:
Optimization of the forging process: By optimizing the forging process, the stress concentration and temperature gradient of the workpiece can be reduced, thereby reducing the risk of material deformation. For example, the plastic deformation of the workpiece can be reduced by multi-directional forging, cumulative rolling and other processes.
Control of heating temperature and speed: Reasonable control of heating temperature and speed can reduce the thermal stress of the workpiece and the formation of oxide skin, thereby reducing the risk of material deformation. For example, the method of segmental heating and slow heating can reduce the thermal stress of the workpiece.
Use a reasonable cooling method: a reasonable cooling method can reduce the thermal stress and tissue deformation of the workpiece, thereby reducing the risk of material deformation. For example, methods such as spray cooling or water quenching can quickly reduce the temperature of the workpiece and reduce thermal stress.
Control of deformation: In the forging process, reasonable control of the deformation of the workpiece can reduce the plastic deformation and stress concentration of the material, thereby reducing the risk of material deformation. For example, the plastic deformation of the workpiece can be reduced by limiting the reduction amount and controlling the reduction speed.
The use of auxiliary processes: The use of auxiliary processes can reduce the stress and deformation of the workpiece, thereby reducing the risk of material deformation. For example, using methods such as prepressing, preheating and lubrication can reduce the stress and friction of the workpiece and reduce the risk of material deformation.
In addition to control technology, process optimization and quality control are also important means to control material deformation in the production of hydropower forgings. Process optimization can reduce the risk of material deformation at the source, while quality control can ensure the quality of the product by detecting and controlling indicators such as the size, shape and performance of the workpiece.
In terms of process optimization, advanced forging equipment and process methods, such as high-speed forging and precision forging, can be used to reduce the stress and deformation of the workpiece. In addition, the forging process can be simulated and optimized by means of numerical simulation and simulation technology to improve the stability and reliability of the process.
In terms of quality control, non-destructive testing, metallographic analysis and other means can be used to conduct comprehensive testing and control of the workpiece to ensure that the quality and performance of the product meet the requirements. In addition, the quality management system and quality traceability system can also be established to carry out comprehensive management and control of product quality.
The material deformation and control technology of hydropower forging production is the key link to improve product quality and production efficiency. By analyzing the causes and effects of material deformation, adopting reasonable control technology and optimizing process flow can effectively control material deformation and improve product quality and production efficiency. In the future, with the continuous development of science and technology and the intensification of market competition, the material deformation and control technology of hydropower forgings 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.
