As an important mechanical part, hot die forging is widely used in various industrial fields. However, in the production process, the forging may appear various failure phenomena, such as cracks, deformation, abnormal organization, etc., which seriously affect the quality and service life of the product. As a systematic research method, failure analysis can help enterprises deeply understand the causes and mechanisms of forging failure, and provide strong support for quality improvement. This paper discusses the application of failure analysis in quality improvement of hot die forging.
Failure analysis is a series of systematic and comprehensive technical activities, the main purpose is to determine the mode and mechanism of product failure, find out the cause of failure, and put forward improvement measures. General failure analysis steps include: failure phenomenon description, macro and micro analysis, chemical composition analysis, mechanical properties test, fracture analysis, etc.
Application of failure analysis in quality improvement of hot die forging
Determine the failure mode and mechanism: Through macroscopic and microscopic observation, determine the failure mode of hot die forging, such as ductile fracture, fatigue fracture, hydrogen embrittlement, etc. By means of fracture analysis and other means, the failure mechanism of forging is revealed and the direction for the subsequent quality improvement is provided.
Find out the cause of failure: combined with the results of chemical composition analysis, mechanical properties test, from the aspects of raw materials, process parameters, equipment conditions, etc., a comprehensive analysis of the cause of forging failure. For example, inclusions in raw materials, improper control of process parameters, etc., can lead to forging failure.
Put forward improvement measures: Based on the analysis results of failure causes, put forward targeted quality improvement measures. For example, optimize raw material selection and treatment process, improve hot die forging process parameters and equipment conditions, and strengthen quality control in the production process.
Verify the effectiveness of the improvement measures: by implementing the improvement measures, the hot die forging production is carried out again, and the quality inspection and failure analysis of the new products are carried out. If the improvement measures are effective, the quality of forgings should be significantly improved, and the failure phenomenon should be effectively controlled.
Taking a hot die forging enterprise as an example, a type of forging produced by the enterprise frequently cracks and failures during use. Through failure analysis, it is found that there are a lot of non-metallic inclusions in the forgings, which seriously affect the mechanical properties of the materials. In response to this problem, the company has improved the processing process of raw materials and strengthened the removal measures of inclusions. After implementing the improvement measures, the quality of newly produced forgings has been significantly improved, and the problem of crack failure has been effectively solved.
Failure analysis plays an important role in quality improvement of hot die forging. Through systematic failure analysis method, we can deeply understand the causes and mechanisms of forging failure, and put forward targeted quality improvement measures for enterprises. This will help improve the quality level of hot die forging, enhance the market competitiveness of products, and promote the sustainable development of the hot die forging industry.
