In this paper, the formation mechanism of defects in hot die forging is studied, and the corresponding control strategy is proposed. Firstly, the common types of defects in hot die forging are introduced, and then the causes and mechanisms of defects are analyzed in detail. Then, the key techniques and methods of controlling defects are discussed, and corresponding control strategies are given. Finally, an example is given to verify the effectiveness of the control strategy.
Hot die forging is an important metal forming process, widely used in automotive, aerospace, energy and other fields. However, in the process of hot die forging, due to the influence of various factors, there are often some defects, such as cracks, folds, pores and so on. These defects not only reduce the quality of the product, but also may lead to production accidents. Therefore, it is of great significance to study the formation mechanism of defects in hot die forging and put forward effective control strategies for improving product quality and production efficiency.
In the process of hot die forging, the common defect types include crack, folding, porosity and so on. The formation of these defects is closely related to material properties, process parameters, mold design and many other factors.
Analysis of the formation mechanism of defects
Cracks: Cracks are formed when the stress on the metal during forging exceeds its strength limit. The main reasons include too high temperature, too fast deformation rate, uneven material organization and so on.
Folding: Folding is formed due to the poor flow of metal in the mold filling process, resulting in local accumulation. The main reasons include unreasonable mold design, poor lubrication, poor metal billet surface quality and so on.
Pores: Pores are formed because the gas inside the metal is not completely discharged during the forging process. The main reasons include the presence of gas in the metal blank, low forging temperature, poor exhaust and so on.
In order to effectively control the defects in the hot die forging process, the following control strategies and methods can be adopted:
Optimization of process parameters: reasonable selection of forging temperature, deformation rate and other process parameters to avoid too high stress and too fast deformation rate resulting in cracks.
Improve the mold design: Optimize the structure and size of the mold to ensure the smooth flow of metal during the mold filling process and avoid folding defects.
Strengthen the lubrication measures: the use of appropriate lubricants, reduce the friction between the metal and the mold, reduce the folding tendency.
Control the quality of metal billet: strictly control the chemical composition, organizational structure and surface quality of metal billet to reduce the source of defects such as porosity and porosity.
The introduction of advanced testing technology: the use of non-destructive testing technology to real-time monitoring of forging process, timely detection of potential defects, take appropriate control measures.
By applying the above control strategy in a hot die forging enterprise, the production process is optimized and improved, and the incidence of defects is successfully reduced. Statistics show that the proportion of defects such as cracks, folds and pores is significantly reduced, product quality is significantly improved, and customer satisfaction is greatly improved. At the same time, the production efficiency has also been improved to a certain extent, which has brought significant economic benefits to the enterprise.
In this paper, the forming mechanism of defects in hot die forging is analyzed, and the corresponding control strategies and methods are put forward. Practice has proved that these control strategies can effectively reduce the incidence of defects in hot die forging process and improve product quality and production efficiency.
