Thermal power forging is an important component in thermal power generation industry, its quality and performance directly affect the operating efficiency and safety of thermal power generation equipment. In order to meet the higher requirements of use, the processing technology in the manufacturing of thermal power forgings has been continuously improved and optimized. This paper will analyze and discuss the processing technology and its improvement in the manufacture of thermal power forgings.
Processing technology introduction
Free forging
Free forging is a forging method that uses the impact force of a hammer or press to deform the metal billet and gradually approach the desired shape. Free forging has the advantages of simple operation and less equipment investment, but the forming accuracy and material utilization rate are low. In thermal forging manufacturing, free forging is mainly used to produce small forgings and simple shaped products.
Die forging
Die forging is a forging method in which metal billets are put into a die and the metal is deformed and filled with the shape of the die by the pressure of the press. The die forging has the advantages of high forming precision and high material utilization rate, but the die manufacturing cost is high. In thermal forging manufacturing, die forging is mainly used to produce large forgings and products with complex shapes.
weld
Welding is a process in which two or more metal parts are joined together. In the manufacture of thermal power forgings, welding is mainly used to repair and connect forgings. Common welding methods include manual arc welding, gas shielded welding and so on.
Process improvement
(1) The use of precision forging technology: precision forging is the use of high-precision molds and advanced forging equipment, so that the metal blank under high pressure to rapidly deform and fill the mold shape of a forging method. The use of precision forging technology can improve the forming accuracy and material utilization rate, reduce the amount of cutting and energy consumption.
(2) Optimization of forging process: By optimizing forging process parameters, such as forging temperature, deformation speed and deformation amount, it can improve the mechanical properties of forgings and reduce microscopic defects. For example, the high temperature forging can reduce the deformation resistance of the material and improve the plasticity of the material; The use of multi-directional forging can increase the deformation uniformity of the material and reduce the stress concentration inside the material.
Equipment renewal
(1) The introduction of advanced forging equipment: The use of advanced forging equipment can improve production efficiency, reduce energy consumption and reduce environmental pollution. For example, the use of hydraulic presses instead of traditional steam hammers can reduce noise and vibration and improve production efficiency; High precision and high efficiency forging can be achieved by using electro-hydraulic servo press.
(2) Automation and intelligent transformation: Through automation and intelligent transformation, the production line can be unmanned and less humanized, improve production efficiency and reduce labor costs. For example, the use of robot automated production lines can realize the whole process of automatic production from raw materials to finished products; Intelligent monitoring system can realize real-time monitoring and fault warning of production process.
Material optimization
(1) The use of high-strength materials: the use of high-strength materials can improve the bearing capacity and service life of the forging. For example, using high-strength alloy steel instead of ordinary carbon steel can improve the yield strength and tensile strength of forgings; The use of wear-resistant materials can increase the wear resistance of forgings.
(2) Development of new materials: Through the development of new materials can meet higher use requirements and environmental requirements. For example, the development of high temperature wear-resistant materials can meet the requirements of high temperature environment; The development of environmentally friendly materials can reduce pollution and harm to the environment.
Difficulty in implementation
(1) Capital investment: The introduction of advanced forging equipment and automated production lines requires a lot of capital investment, and the financial strength of enterprises is higher.
(2) Technical difficulty: The use of precision forging technology and optimization of forging process requires a high level of technology and rich experience, and the technical research and development ability of enterprises is required.
(3) Personnel training: The adoption of automated and intelligent production lines requires training and skill upgrading of employees, which requires higher training and management capabilities of enterprises.
Effect evaluation
(1) Improve the forming accuracy and material utilization rate: The use of precision forging technology and optimization of forging process can improve the forming accuracy and material utilization rate, reduce the amount of cutting and energy consumption, thereby reducing production costs and improving product quality.
(2) Improve production efficiency and product quality: The introduction of advanced forging equipment and automated production lines can improve production efficiency and product quality, reduce manual operation and human error, thereby improving production efficiency and product quality.
(3) Reduce environmental pollution and human costs: The use of automation and intelligent production lines can reduce environmental pollution and human costs, improve the competitiveness of enterprises and sustainable development capabilities.
This paper introduces the processing technology of thermal power forging and its improvement measures. The forming accuracy, material utilization rate, production efficiency and product quality of thermal power forgings can be improved through the implementation of process improvement, equipment updating and material optimization, and environmental pollution and labor cost can be reduced. In the future, with the continuous development of science and technology and the continuous improvement of environmental protection requirements, the processing technology in thermal power forging manufacturing will continue to improve and innovate, and make greater contributions to the sustainable development of enterprises and the improvement of the social environment.
