The production process of petrochemical forgings has a crucial impact on the quality and performance of the product. However, the traditional production process often relies on experience and practice, and it is difficult to achieve the optimal selection of process parameters. With the development of computer technology, numerical simulation technology is gradually applied to the production process optimization of petrochemical forgings. This paper aims to discuss the method and application of optimization of petrochemical forging production process based on numerical simulation, in order to provide guidance for practical production.
Numerical simulation technology is a simulation method based on computer models, which can simulate the physical field distribution such as deformation, temperature and stress during the processing of materials, so as to predict the quality and performance of products. In the production process of petrochemical forgings, numerical simulation technology can be applied in the following aspects:
Mold design optimization: By simulating the flow and filling process of materials, optimize the structure and size of the mold, improve the forming quality and efficiency of the forging.
Heating process optimization: By simulating the heating process of the material, determine the best heating temperature and time, avoid overheating or overburning of the material, and ensure the internal quality and mechanical properties of the forging.
Forging process optimization: Through the simulation of material deformation and flow process, determine the best forging speed and pressure, avoid forging cracks, folding and other defects, improve the forming quality and mechanical properties of forging.
Cooling process optimization: By simulating the cooling process of materials, determine the best cooling speed and time, avoid residual stress and deformation of forgings, and ensure the dimensional accuracy and stability of forgings.
Taking the flange forgings produced by a petrochemical enterprise as an example, numerical simulation technology was used to optimize the production process. The specific steps are as follows:
Establish mathematical model: According to the geometry and material characteristics of flange forgings, establish mathematical model, including die, material, boundary conditions and other parameters.
Numerical simulation: Finite element method is used to simulate the heating, forging and cooling process of flange forgings, and to analyze the distribution of physical fields such as temperature, stress and strain.
Optimization process parameters: According to the numerical simulation results, adjust the heating temperature, forging speed and pressure, cooling speed and time and other process parameters, so that the forming quality and mechanical properties of flange forgings to achieve the best.
Experimental verification: The forming quality and mechanical properties of flange forgings were tested and analyzed by using the optimized process parameters to verify the accuracy and reliability of the numerical simulation results.
Production process optimization of petrochemical forgings based on numerical simulation can effectively improve product quality and performance, and reduce production cost and energy consumption. However, there are still some problems and challenges in the practical application of numerical simulation technology, such as model accuracy, calculation efficiency, data processing and so on. In the future, with the continuous development and improvement of computer technology and numerical simulation technology, the optimization of petrochemical forging production process based on numerical simulation will be more widely used and promoted, and make important contributions to promoting the sustainable development of the petrochemical industry.
