Warm forging technology is an advanced metal forming process, which has been widely used in manufacturing various kinds of high precision and high strength forgings. Especially in the production of complex shape forgings, warm forging technology has shown its unique advantages. However, at the same time, the technology also has some limitations. In this paper, the advantages and limitations of warm forging technology in the production of complex forgings will be deeply discussed in order to provide useful reference for the research and practice in related fields.
Advantages of warm forging technology in complex shape forging production
Improve the formability of the material: The warm forging technology makes the metal material have better plasticity and formability at the appropriate temperature by precisely controlling the heating temperature. This allows complex shapes of forgings to be more easily formed through the die, reducing the risk of defects such as material cracking and folding.
Optimized metal flow line distribution: In the warm forging process, the metal flow line can be distributed along the mold profile, making the mechanical properties of the forging more uniform. This feature is particularly important for the production of complex shape forgings subjected to complex stresses, such as aeroengine blades, automotive crankshafts, etc.
Improve dimensional accuracy and surface quality: Warm forging technology adopts die forming, which can achieve near-net forming of forgings and reduce subsequent machining allowance. This improves the dimensional accuracy and surface quality of the forging, and reduces the production cost and cycle time.
Suitable for a variety of materials: Warm forging technology is suitable for a variety of metal materials, including steel, aluminum, copper, titanium and so on. This allows the technology to meet the diverse needs of different industries for complex shape forgings.
Limitations of warm forging technology in the production of complex forgings
Mold manufacturing is difficult: Because the mold structure of complex shape forgings is complex, manufacturing is difficult and the cost is high. This limits the application of warm forging technology in some fields to some extent.
High requirements for process parameter control: warm forging technology has very strict requirements for the control of process parameters such as heating temperature, forging speed and cooling speed. The deviation of any parameter may lead to the instability of forging quality. Therefore, producers need to have a wealth of experience and expertise to ensure the stability of the warm forging process and the quality of the forgings.
Relatively low production efficiency: Because the warm forging technology requires precise control of multiple process parameters, production efficiency is relatively low. Especially for mass production, warm forging technology may not be as economical as other forming processes.
There are certain requirements for material performance: Although warm forging technology is suitable for a variety of metal materials, for some materials with special performance requirements (such as superalloys, ultra-high strength steel, etc.), it may be necessary to further optimize the process parameters and material composition to meet their special performance requirements.
In summary, warm forging technology has significant advantages in the production of complex forgings, such as improving the formability of materials, optimizing the distribution of metal flow lines, improving dimensional accuracy and surface quality. However, this technology also has some limitations, such as the difficulty of mold manufacturing, high requirements for process parameter control, relatively low production efficiency and certain requirements for material properties. In order to fully exploit the potential of warm forging technology and overcome its limitations, future research directions can include: developing new mold materials and manufacturing technologies to reduce mold manufacturing costs; Research on intelligent control technology to improve the stability of process parameters and production efficiency; Explore new materials and processes to meet special performance requirements; Strengthen interdisciplinary cooperation to promote the integration of warm forging technology with other advanced manufacturing technologies.
