Thermal forging is a key component in thermal power generation industry, and its quality directly affects the operating efficiency and safety of thermal power generation equipment. In recent years, with the adjustment of energy structure and the growth of power demand, the quality requirements for thermal power forgings are also increasing. Therefore, it is of great significance to improve the production process and product quality of thermal power forgings to meet the market demand and enhance the competitiveness of enterprises.
The production process of thermal power forgings mainly includes raw material preparation, forging, heat treatment, machining and other links. At present, China’s thermal power forging production enterprises in the process technology and equipment level there are large differences, some enterprises of the production process is relatively backward, resulting in unstable product quality, can not meet the needs of the high-end market. Therefore, improving the production process of thermal power forgings and improving product quality is an important task for the development of the current industry.
Process flow and existing problems
Raw material preparation: high quality alloy steel is used as raw material, and after pre-treatment such as cutting and grinding, it enters the forging process. The problem is that the utilization rate of materials is low and the waste is serious.
Forging: Using the traditional free forging process, through heating, forging, cooling and other steps to form the required forging shape. The problem is that the temperature control in the forging process is not accurate, resulting in uneven internal organization of the forging, affecting the quality of the product.
Heat treatment: Heat treatment processes such as quenching and tempering are used to adjust the internal structure and mechanical properties of forgings. The existing problem is that the heat treatment equipment is backward and the temperature control is inaccurate, resulting in unstable product performance.
Machining: The use of CNC machine tools and other equipment to finish forging to meet the requirements of drawings. The problem is that the processing allowance is too large, wasting materials and time.
Improve the scheme and implementation effect
Raw material preparation: Advanced cutting and grinding equipment is used to improve material utilization and reduce waste. After implementation, the material utilization rate increased by 10%.
Forging: The introduction of advanced forging equipment and technology, the use of accurate temperature control system to ensure that the internal organization of the forging uniform. After the implementation, the quality of forgings has been significantly improved, and the qualified rate of products has increased by 20%.
Heat treatment: Update heat treatment equipment and adopt advanced temperature control system to ensure stable product performance. After implementation, the performance of the product has been significantly improved, and the strength and wear resistance indicators have been improved.
Machining: Optimize processing procedures, reduce processing allowance, improve material utilization. After implementation, processing efficiency was increased by 15% and material waste was reduced by 20%.
Product quality impact
By improving the process flow and implementing the optimization scheme, the product quality of thermal power forging has been significantly improved. It is manifested in the following aspects:
Improved material utilization: By improving raw material preparation and machining links, the material utilization rate has increased by more than 10%, reducing the waste of resources.
Improved product pass rate: through the introduction of advanced forging equipment and process, as well as optimization of heat treatment links, the product pass rate increased by more than 20%, reducing the number of unqualified products.
Product performance improvement: Through the use of advanced forging and heat treatment process, product performance has been significantly improved, strength and wear resistance indicators have been improved to meet the needs of the high-end market.
Production efficiency improvement: By optimizing processing procedures and reducing processing allowance and other measures, production efficiency has been increased by more than 15% and product delivery cycle has been shortened.
The improvement of production process of thermal power forging is of great significance to improve product quality and enterprise competitiveness. Through the introduction of advanced equipment and technology, optimize the production process and other measures, can achieve the improvement of material utilization rate, product pass rate, product performance improvement and production efficiency improvement. Therefore, enterprises should pay attention to process improvement, continuously invest capital and human resources, promote technological innovation and industrial upgrading, in order to achieve sustainable development.
