In the petrochemical industry, the production of forgings cannot be separated from the use of molds. As an important tool for forging, the life of die directly affects the production cost and production efficiency of forging. However, due to the harsh conditions of high temperature, high pressure and corrosive media involved in the manufacturing process of petrochemical forgings, the life of the die is often seriously affected. Therefore, extending the service life of the die has become an important research topic. This paper will discuss the method of life extension of petrochemical forging die, in order to provide useful reference for related enterprises and research institutions.
Influencing factors of die life
Mold material: The choice of mold material is one of the key factors affecting the life of the mold. Different materials have different high temperature resistance, corrosion resistance and mechanical properties, so it is necessary to choose the appropriate mold material according to the specific conditions of use.
Forging process: forging process includes heating temperature, forging speed, deformation and other parameters. The selection of these parameters directly affects the stress and temperature distribution of the mold, and thus affects the life of the mold.
Cooling and lubrication: Cooling and lubrication conditions also have an important impact on the life of the mold. Proper cooling can reduce the temperature of the mold, reduce thermal stress and thermal fatigue; And good lubrication can reduce the friction and wear between the mold and the forging.
Use environment: In the manufacturing process of petrochemical forgings, the mold needs to withstand the harsh environment such as high temperature, high pressure and corrosive media. These environmental factors will lead to oxidation, corrosion and fatigue damage of the mold, thereby shortening the service life of the mold.
Method of mould life extension
Optimize mold materials: Select mold materials with high temperature resistance, corrosion resistance and excellent mechanical properties, such as high-speed steel, cemented carbide, etc. At the same time, coating technologies such as physical vapor deposition (PVD) or chemical vapor deposition (CVD) can be considered to form a protective layer on the surface of the mold to improve the wear and corrosion resistance of the mold.
Improve the forging process: optimize the forging process parameters, such as heating temperature, forging speed and deformation, to reduce the stress of the mold and reduce the temperature gradient. The forging process was simulated and analyzed by numerical simulation technology to predict and optimize the process parameters.
Enhanced cooling and lubrication: Improve the cooling system and use more effective cooling methods, such as internal cooling or spray cooling, to reduce the operating temperature of the mold. At the same time, the appropriate lubricant is selected to reduce the friction and wear between the mold and the forging.
Improve the level of mold maintenance: regular inspection and maintenance of molds, timely detection and treatment of mold cracks, wear and other damage. Repair damaged molds with repair techniques such as welding, grinding and EDM to extend their service life.
Introduction of advanced technology: The use of advanced manufacturing techniques, such as precision forging, 3D printing, etc., to create more complex and accurate molds. These technologies can reduce the difficulty and cost of mold manufacturing, while improving the quality and life of the mold.
Training and management: Strengthen the training and management of operators to improve their skill level and operational awareness. Ensure that the operator uses and maintains the mold correctly to reduce the impact of human factors on the life of the mold.
Prolonging the service life of petrochemical forging die is an important research topic. By optimizing mold materials, improving forging process, strengthening cooling and lubrication, improving mold maintenance level, introducing advanced technology and strengthening training and management, the service life of the mold can be effectively extended to reduce production costs and improve production efficiency. In the future, with the continuous development of new material technology and intelligent manufacturing technology, the life extension method of petrochemical forging die will usher in more innovations and breakthroughs to provide a strong guarantee for the development of the petrochemical industry.
