As an important part of locomotive power system, the performance of main and auxiliary connecting rod directly affects the running stability and safety of locomotive. Forging is a key link in the manufacture of locomotive main and auxiliary connecting rod, but the possible defects in the forging process will affect the performance of connecting rod. This paper discusses the influence of forging defects on the performance of main and auxiliary connecting rod of locomotive and the corresponding preventive measures.
Influence of forging defects on the performance of main and auxiliary connecting rod of locomotive
Surface cracking: Surface cracking is one of the common defects in the forging process. It will lead to the strength and durability of the connecting rod decline, easy to cause stress concentration and fatigue fracture.
Internal holes: During the forging process, if the metal flow is not uniform or the filling is insufficient, it may lead to holes inside the connecting rod. This will reduce the mechanical properties of the connecting rod, affecting its bearing capacity and service life.
Inclusions: Inclusions are other substances entrainment in the connecting rod material. Inclusion will destroy the continuity of the material and reduce the mechanical properties and fatigue strength of the material.
Folding and creasing: During the forging process, metal folding or creasing will cause stress within the material, reducing the fatigue strength and service life of the material.
Size deviation: If there is a size deviation in the forging process, it may lead to difficulties in connecting rod assembly or a decrease in fitting accuracy. This will affect the working performance and stability of the connecting rod.
Measures to prevent forging defects
Strict control of raw materials: the selection of high-quality materials as raw materials for forging to ensure its high purity and less impurities. Strict quality inspection and control of raw materials to prevent unqualified materials from entering the production process.
Optimization of forging process: According to the shape and size requirements of the connecting rod, develop a reasonable forging process. Optimize mold design to ensure uniform metal flow and adequate filling. Adopt appropriate forging temperature and processing pressure to prevent defects caused by too high temperature or insufficient pressure.
Quality inspection and control: real-time monitoring in the forging process to ensure that the process parameters meet the requirements. Inspect the appearance and measure the dimensions of the forged connecting rod, find and deal with the defects in time. At the same time, a sound quality management system is established to ensure the effective implementation of quality control.
Tempering treatment: After forging is completed, the connecting rod is tempered to eliminate internal stress and improve the toughness of the material. The tempering treatment should be carried out at the specified temperature and time to ensure the stable performance of the connecting rod.
Surface treatment: The surface of the connecting rod is polished, shot peening and other treatments to improve its fatigue resistance and service life. At the same time, the surface defects are repaired and filled to ensure the integrity of the connecting rod surface.
In this paper, the influence of forging defects on the performance of locomotive main and auxiliary connecting rod and the preventive measures are deeply discussed, and the following conclusions and suggestions are drawn:
Strengthen the monitoring of the forging process: through the introduction of advanced monitoring equipment and process control system, real-time monitoring of the temperature, pressure and other parameters in the forging process, timely detection of anomalies and adjustments to prevent defects.
Improve the skill level of operators: regular training and skill assessment of operators to ensure that they are proficient in forging process and equipment operation skills, and can operate in accordance with standard procedures to reduce the possibility of human factors leading to defects.
Continuous improvement and innovation: With the continuous progress of technology and changes in market demand, forging process should continue to improve and innovate. By introducing new process technology, optimizing process parameters and improving production automation level, the forging quality and efficiency are improved to meet the increasingly strict performance requirements of locomotive main and auxiliary connecting rod.
