Forging production is an important link in the machinery manufacturing industry, and the mold is the core component of forging production. The mold will wear during use, which not only affects the quality of the forging, but also may lead to the failure of the mold. Therefore, it is very important to monitor and maintain mold wear. This paper will discuss the die wear monitoring and maintenance in forging production from the aspects of die wear monitoring, die maintenance, die replacement and so on.
Die wear is an important factor affecting forging quality. Wear will make the surface of the mold become rough, reduce the accuracy and surface quality of the forging. In order to detect mold wear in time, the following monitoring methods can be adopted:
Observation method: Observe the gloss and roughness of the surface of the mold, if the surface loses luster or becomes rough, it indicates that the mold may have been worn.
Measurement method: The key parts of the mold are measured by measuring tools. If the size changes, it indicates that the mold has been worn.
Flaw detection method: The use of ultrasonic, X-ray and other non-destructive testing equipment to detect the mold, you can find cracks, peeling and other defects inside the mold.
In the monitoring process, if the mold is found to be seriously worn or defective, it should be maintained and replaced in time to avoid affecting the quality of the forging.
Mold maintenance is divided into two categories: preventive maintenance and repair maintenance. Preventive maintenance is to extend the service life of the mold and reduce wear; Repair maintenance is to restore the performance of the mold and eliminate the effects of wear. Specific maintenance measures include:
Preventive maintenance: Regular cleaning, lubrication, rust prevention of the mold to keep the mold surface clean and smooth. In addition, measures such as surface strengthening treatment and coating protection can also be taken to improve the wear resistance and fatigue resistance of the mold.
Repair maintenance: To repair the worn mold, you can use grinding, polishing, EDM and other methods to remove the wear layer and restore the size and surface quality of the mold. For severely worn or defective molds, partial replacement or overall replacement can be carried out.
In the maintenance process, attention should be paid to the use of appropriate tools and methods to avoid secondary damage to the mold. At the same time, maintenance records should also be made in order to track and manage the use of the mold.
When the mold is badly worn or cannot be repaired, it needs to be replaced. Mold replacement involves spare parts management, mold change process and risk control. The specific replacement steps are as follows:
Spare parts management: According to the production plan and the use of the mold, prepare the mold spare parts that need to be replaced in advance. Make sure the size, material, heat treatment and other parameters of spare parts are consistent with the original mold.
Mold change process: First, the worn mold is removed from the production line, and cleaned and inspected. Then, the new mold spare parts are installed on the production equipment, and debugging and calibration are carried out. Finally, trial production is carried out to ensure that the new mold can meet the production requirements.
Risk control: In the process of mold change, attention should be paid to operation safety and equipment maintenance. Avoid equipment damage or personal injury due to improper operation. At the same time, attention should also be paid to controlling the quality and environmental factors in the production process to ensure that the quality of forging meets the requirements.
In the process of replacement, attention should be paid to coordination and communication with other links on the production line to ensure the smooth progress of the mold change process. At the same time, replacement records should also be made in order to track and manage the use of the mold.
The monitoring and maintenance of die wear in forging production is an important measure to guarantee the quality of forging and extend the service life of die. By monitoring and maintaining die wear, problems can be found and solved in time to avoid the impact on forging quality. In the actual production process, appropriate monitoring methods and maintenance measures should be selected according to the specific situation, and relevant records and management should be done well. In addition, the training and management of operators should be strengthened to improve their awareness and skill level of mold wear monitoring and maintenance. Through the effective implementation of these measures, the efficiency and quality of forging production can be further improved.
