In the metal warm forging process, forging cracking is a common quality problem, which not only affects the appearance and performance of the product, but also may cause the increase of production cost and the delay of delivery. In this paper, the causes of cracking of warm forging parts are analyzed from many angles, and corresponding solutions are proposed to help enterprises prevent and solve this problem.
Cracking cause analysis
Raw material problems: If there are quality problems in raw materials, such as uneven chemical composition, presence of inclusions or coarse grains, it may lead to cracking of forgings.
Improper heating temperature: too high or too low heating temperature may cause forging cracking. Excessive temperature will cause the material to overheat, reduce its plasticity; However, too low temperature will increase the hardness of the material and increase the deformation resistance.
Too fast cooling speed: The cooling speed of forgings after warm forging is also a reason for cracking. Rapid cooling will cause the temperature difference between the inside and outside of the material to be too large, resulting in thermal stress, which will lead to cracking.
Improper forging process: the forging process parameters such as pressure, speed, deformation, etc., will affect the quality of the forging. If the parameters are set improperly or the operation is improper, it may cause the forging to crack.
Equipment problems: Equipment problems such as mold wear, equipment accuracy decline, etc., may also lead to forging cracking.
solution
Strict control of raw material quality: strict quality testing and control of raw materials to ensure that their chemical composition is uniform, no inclusions and fine grains. Long-term relationships can be established with reliable suppliers to ensure the stable supply and quality of raw materials.
Optimize the heating process: according to the characteristics of the material and forging requirements, develop a reasonable heating process to ensure that the heating temperature is moderate and uniform. Advanced heating equipment and technology can be used, such as induction heating, resistance heating, etc., to improve heating efficiency and temperature control accuracy.
Control the cooling speed: After the warm forging, use the appropriate cooling speed and way to avoid the temperature difference between the inside and outside of the material is too large. Cooling methods such as water quenching and oil quenching can be used, and adjusted according to the characteristics and thickness of the material.
Optimization of forging process: According to the characteristics of materials and product requirements, develop reasonable forging process parameters and operating specifications. The forging process can be numerically simulated and optimized to improve the forming quality and performance of the forging.
Regular maintenance and inspection of equipment: regular inspection and maintenance of molds, equipment, etc., to ensure that they are in good working condition. Timely replacement or repair of severely worn molds, adjustment or update of equipment with reduced accuracy.
Strengthen staff training and management: strengthen staff technical training and management, improve staff quality awareness and operational skills. Regular training and assessment can be organized to ensure that employees are proficient in forging process and operating specifications.
Establish quality management system: Establish a sound quality management system, including raw material testing, process control, finished product inspection and other links. Identify and resolve potential quality problems through regular quality inspection and evaluation.
Strengthen cooperation with scientific research institutions: Establish cooperative relations with scientific research institutions to jointly research and develop new warm forging processes and materials. Through the introduction of advanced technology and equipment, improve the technical level of enterprises and market competitiveness.
The prevention of cracking of warm forging parts needs comprehensive control and management from many aspects. By strictly controlling the quality of raw materials, optimizing the heating and cooling process, adjusting the forging process parameters, strengthening the maintenance and management of equipment, etc., the problem of forging cracking can be effectively prevented and solved. In the future, with the continuous progress of science and technology and the expansion of application scenarios, more advanced technologies and methods will be applied to warm forging process to help enterprises improve product quality and production efficiency.
