As the core component of key equipment, the dimensional accuracy and shape control of petrochemical forgings are very important to the performance and safety of the whole equipment. However, due to various factors in the forging process, such as material properties, heating and forging processes, cooling methods, etc., may lead to deviations in the size and shape of the forgings. This paper discusses the importance of dimensional accuracy and shape control of petrochemical forgings, analyzes the influencing factors, and puts forward corresponding control measures to improve the quality and performance of forgings.
The importance of dimensional accuracy and shape control of petrochemical forgings
Equipment performance: The dimensional accuracy and shape control of the forging directly affect the assembly and operation performance of the equipment. Size deviation may lead to inappropriate fit clearance, affecting the sealing and transmission efficiency of the equipment; Shape deviation can cause stress concentration and reduce the load carrying capacity of the equipment.
Safety: Petrochemical equipment works in harsh environments such as high temperature, high pressure and corrosion, and the dimensional accuracy and shape control of forgings are crucial to the safety of equipment. Size and shape deviations may lead to deformation, cracking and other safety problems during service.
Economy: Forgings with good dimensional accuracy and shape control can reduce processing allowance, reduce material consumption and manufacturing costs. At the same time, high-quality forgings can improve the service life and maintenance cycle of equipment, and reduce operating costs.
The main factors affecting dimensional accuracy and shape control
Material properties: The chemical composition, organizational structure and mechanical properties of the material will affect the dimensional accuracy and shape control of the forging. The properties of the material such as thermal expansion coefficient and shrinkage rate have a significant influence on the dimensional accuracy.
Heating and forging process: The control of process parameters such as heating temperature, holding time and forging speed is crucial to the dimensional accuracy and shape control of forgings. Improper heating and forging processes can result in large or small forgings and irregular shapes.
Cooling method: The cooling method and cooling speed also have an important impact on the dimensional accuracy and shape control of the forging. Rapid cooling may lead to excessive internal stress of forging, resulting in deformation and cracking; Slow cooling may result in a larger size.
Equipment accuracy: The accuracy and maintenance status of forging equipment will also affect the dimensional accuracy and shape control of forging parts. Problems such as wear and loosening of the equipment may lead to deviations in the size and shape of the forging.
Control measures and strategies
Optimize material selection: According to the working conditions and performance requirements of the equipment, select the appropriate material to ensure that the chemical composition, organizational structure and mechanical properties of the material meet the requirements. For large forgings, material pretreatment technology, such as homogenizing annealing, normalizing, etc. can be considered to improve the structure and properties of the material.
Strict control of heating and forging process: formulate reasonable heating and forging process parameters to ensure that heating temperature, holding time, forging speed, etc. are controlled in a suitable range. Advanced heating and forging technologies, such as induction heating and precision forging, are used to improve the dimensional accuracy and shape control of forgings.
Optimize the cooling method: according to the material and shape of the forging, choose the appropriate cooling method and cooling speed. For large forgings, fractional cooling or water mist cooling can be used to reduce stress concentration and thermal deformation during cooling.
Improve equipment accuracy and maintenance level: regular maintenance and overhaul of forging equipment to ensure the accuracy and stability of equipment. Adopt advanced measurement and control technology, such as laser scanning, numerical control technology, to monitor and adjust the size and shape of the forging in real time.
Strengthen quality inspection and evaluation: Establish a sound quality inspection system to comprehensively detect and evaluate the dimensional accuracy and shape of forgings. Non-destructive testing technology, such as ultrasonic testing, magnetic particle testing, etc., is used to check and evaluate the internal quality and surface quality of the forging. For unqualified products, timely repair or scrap treatment.
Strengthen employee training and management: improve the professional skills and quality awareness of employees, strengthen the monitoring and management of the production process to ensure that the control measures are effectively implemented. Establish an incentive mechanism to encourage employees to put forward suggestions and suggestions to continuously improve the production process and product quality.
The dimensional accuracy and shape control of petrochemical forgings is one of the key tasks in the manufacturing process, which is related to the quality and performance of the whole equipment.
