Forgings are important parts in the machinery manufacturing industry, and their quality directly affects the performance and safety of the final product. In the forging production process, due to the influence of many factors, it is easy to produce various forging defects. These defects not only affect the appearance and quality of the forgings, but also may cause the performance of the forgings to decline or fail. Therefore, it is very important to conduct in-depth analysis of forging defects and take effective preventive measures. In this paper, the analysis of forging defects and preventive measures will be discussed to provide guidance for forging production.
Forging defect analysis
crack
Crack is one of the most common defects in forging production, which is mainly divided into surface crack and internal crack. Surface cracks are usually caused by rough mold surfaces, poor lubrication, or high forging temperatures. Internal cracks may be caused by the presence of inclusions in the material, the forging temperature is too low or the forging speed is too fast.
fold
Folding is a defect on the forging surface, which is mainly manifested as local accumulation or folding pattern. Folding is usually caused by unreasonable mold design, poor lubrication or high forging temperature.
Cannot fill one’s fill
Filling dissatisfaction means that the forging fails to fully fill the shape of the mold during the forging process, which is manifested as local lack of material or depression. The result of insufficient filling may be caused by low forging temperature, insufficient plasticity of material or unreasonable mold design.
overburning
Overburning refers to the phenomenon of coarse grain and decreased performance in the forging process due to high temperature. The occurrence of overburning may be caused by too high forging temperature or too long holding time.
Preventive measure
Optimize mold design
Reasonable mold design can effectively reduce forging defects. In the mold design, the plasticity, fluidity and forming characteristics of the material should be fully considered, and the geometric shape and size of the mold should be reasonably designed to avoid the defects caused by the rough surface of the mold or the unreasonable design.
Control forging temperature
Reasonable forging temperature is an important factor to ensure forging quality. In the forging process, the forging temperature should be strictly controlled to avoid defects caused by too high or too low temperature. At the same time, the heating speed and holding time should also be reasonably controlled to prevent the occurrence of overburning.
Strengthen lubrication management
Good lubrication can reduce the friction between the mold and the material and avoid defects such as cracks or folding during the forming process of the material. Therefore, lubrication management should be strengthened in the production process, and appropriate lubricants should be selected to ensure that the cleanliness and dosage of lubricants are moderate.
Improve the quality of operators
The skill level and responsibility of the operator directly affect the quality of the forging. Therefore, it is necessary to strengthen the training and management of operators, improve their skill level and sense of responsibility, and ensure that each operation step meets the process requirements.
Improve the quality management system
Establishing a sound quality management system can effectively guarantee the quality of forgings. In the production process, each link should be strictly controlled and inspected to discover and deal with potential problems in a timely manner. At the same time, the production equipment, molds and processes should also be inspected and maintained regularly to ensure the stability and reliability of the production process.
In view of the above preventive measures, the following implementation plans can be formulated:
Optimize the mold design to ensure that the mold geometry and size is reasonable and the surface quality is good. At the same time, regular inspection and maintenance of the mold, timely repair of worn or damaged molds.
Formulate a strict forging temperature control system, and strictly control the heating speed and holding time. At the same time, the advanced temperature measuring equipment is used to monitor the forging temperature in real time to ensure that the forging temperature is controlled within a reasonable range.
Strengthen the lubrication management, choose the appropriate lubricant, and regularly check and replace the lubricant. At the same time, the application method and dosage of lubricant are strictly controlled to ensure good lubrication effect.
Conduct systematic training and management for operators to improve their skill level and responsibility. At the same time, the use of performance assessment and other ways to motivate operators to perform their duties.
Establish a sound quality management system, strict control and inspection of each production link. At the same time, regular inspection and maintenance of production equipment, molds and processes to ensure the stability and reliability of the production process.
In this paper, the forging defects in forging production are deeply analyzed, and the corresponding preventive measures and implementation schemes are put forward. Through the effective implementation of optimizing mold design, controlling forging temperature, strengthening lubrication management, improving the quality of operators and improving the quality management system, the forging defects can be effectively reduced and the quality and performance of forging parts can be improved. Therefore, in the actual production process, we should pay full attention to the prevention and control of forging defects to ensure that the quality of forging meets the requirements.
