In metal processing manufacturing, warm forging process is widely used in the production of various forgings because of its unique advantages. However, how to ensure that the quality of these forgings meets the required standards is an important issue for manufacturers. This paper will discuss the key factors of quality control of warm forging parts, and put forward the corresponding strategies.
Key factor
Raw material quality: The quality of raw materials directly determines the quality of forgings. If the raw material is defective or has too many impurities, the quality of the final product may be affected, even if the best warm forging process is used.
Heating process control: In the warm forging process, the control of heating temperature and holding time is very important. If the temperature is too high or the holding time is too long, it may cause the metal grain to grow, which affects the mechanical properties of the forging. Conversely, if the temperature is too low or the holding time is too short, the metal may not be able to soften sufficiently, resulting in cracks during the forging process.
Forging pressure and speed: The pressure and speed in the forging process also have an important impact on the quality of the forging. Insufficient pressure may result in the metal not being able to fill the mold completely, while too much pressure may result in mold damage or forging deformation. Similarly, the forging speed also needs to be precisely controlled to ensure that the metal flows evenly in the mold.
Cooling and heat treatment: The cooling and heat treatment process after forging is completed also has an impact on the quality of the forging. Too fast a cooling rate may result in stress within the forgings, while too slow a cooling rate may result in coarse grains. Heat treatment, such as tempering and quenching, can change the internal structure and performance of the forgings, so it also needs to be strictly controlled.
Quality control strategy
Select high quality raw materials: Manufacturers should choose reputable suppliers and carry out strict quality testing on each batch of raw materials. For example, methods such as ultrasonic detection and magnetic particle detection can be used to check the internal defects and impurities of raw materials.
Optimize the heating process: By precisely controlling the heating temperature and holding time, the metal has the best plasticity in the semi-solid state. In addition, advanced heating equipment and technologies, such as induction heating or resistance heating, can be used to improve heating efficiency and uniformity.
Control forging pressure and speed: according to the characteristics of the metal and the requirements of the mold, develop reasonable forging process parameters. During the forging process, the forging pressure and speed can be monitored in real time using displacement sensors and pressure sensors to ensure that it is in the best condition.
Optimize the cooling and heat treatment process: according to the material and requirements of the forging, choose the appropriate cooling speed and heat treatment process. For example, different quenching methods such as water quenching or oil quenching can be used to achieve the best internal structure and properties. In addition, advanced heat treatment equipment and technologies, such as vacuum heat treatment and controlled atmosphere heat treatment, can be used to improve the efficiency and effect of heat treatment.
Implement comprehensive quality testing: In addition to the above measures, it is also necessary to conduct comprehensive quality testing for each batch of forgings. This includes appearance inspection, dimensional measurement, mechanical property testing and metallographic structure observation. By using a combination of non-destructive testing methods and destructive testing methods, the quality of the forgings can be ensured to meet the requirements.
Establish a quality management system: In order to maintain high-quality forging production for a long time, manufacturers need to establish a sound quality management system. This includes developing strict quality standards and operating procedures, training employees to improve quality awareness, and implementing continuous improvement plans. Through regular internal and external audits, the effectiveness and continuous improvement of the quality management system can be ensured.
Warm forging is an important metalworking method, but it is not easy to produce high quality forgings. By focusing on key factors such as raw material quality, heating process control, forging pressure and speed, and cooling and heat treatment, and adopting appropriate quality control strategies, manufacturers can effectively improve the quality of warm forging forgings and meet customer needs.
