As an important basic part in the industrial field, the production process of forging involves a lot of energy consumption. With the continuous improvement of environmental awareness and the rise of energy costs, energy-saving technology is becoming more and more important in the forging production process. This paper will analyze the current situation and existing problems of energy consumption in the forging production process, explore feasible energy-saving technology, and further explain the importance and feasibility of energy-saving technology through case analysis.
I. Energy consumption analysis
The energy consumption in forging production is mainly concentrated in heating, pressure processing and cooling. Among them, the heating link includes heating the raw material to a high temperature state to achieve plastic deformation; The pressure processing process includes forging, stamping and other operations, and plastic deformation of the heated material to obtain the desired shape and performance; The cooling link is to cool the forged parts after processing to achieve the stability of its performance.
In these three links, the main energy waste and inefficiency problems include:
Heating link: The traditional electric furnace heating method is low in efficiency, resulting in a lot of energy waste. At the same time, due to the uneven furnace temperature and too long heating time, it is easy to cause overheating and burning of raw materials.
Pressure processing link: Some forging equipment in the operation of insufficient load, resulting in low energy utilization. In addition, the traditional manual operation is easy to cause material waste and low yield.
Cooling link: most forgings use natural cooling mode, which is inefficient and easy to produce quality differences. At the same time, too fast cooling speed may lead to the increase of the internal stress of the forging, affecting its performance.
Second, energy-saving technology introduction
To solve the above problems, the following energy-saving technologies can be adopted:
Optimization of heating temperature: The use of advanced electric heating technology, such as electromagnetic induction heating and infrared heating, to improve heating speed and energy efficiency, reduce energy waste.
Pressure control: Use high-precision pressure control equipment to achieve accurate control of pressure during forging to reduce energy consumption.
Improved cooling method: The use of forced cooling technology, such as water cooling, oil cooling, etc., to improve cooling speed, reduce cooling time and energy consumption.
Waste heat recovery: The waste heat generated in the forging process is used for secondary utilization, such as preheating raw materials, heating, etc., to achieve energy recycling.
Equipment upgrade: The introduction of high-efficiency, low-energy forging equipment, improve equipment operation efficiency, reduce energy consumption.
In the application of energy-saving technology, it is necessary to consider the feasibility of technology and economic cost. For example, although the forced cooling technology can improve the cooling speed, it needs to increase the cooling equipment and cooling media, resulting in increased costs; Although the waste heat recovery technology can realize the recycling of energy, it needs to consider the stability of the waste heat and the investment cost of the recovery equipment.
Iii. Case analysis
Take a forging factory as an example, the factory mainly produces various mechanical parts. In the production process, the energy consumption of heating, pressure processing and cooling is large. In order to reduce energy consumption and improve energy efficiency, the plant has adopted the following energy-saving measures:
Optimization of heating temperature: The use of electromagnetic induction heating technology to heat raw materials, improve the heating speed and energy efficiency, while avoiding problems such as uneven furnace temperature and overheating of raw materials.
Pressure control: The selection of high-precision hydraulic press instead of traditional forging equipment, to achieve accurate control of pressure, effectively improve the yield and material utilization.
Improved cooling method: The use of forced cooling technology to accelerate the forging cooling speed, shorten the cooling time and energy consumption, while avoiding the problem of internal stress caused by too fast cooling.
Waste heat recovery: The waste heat generated in the forging process is reused through the waste heat recovery equipment, such as preheating raw materials, heating, etc., to realize the recycling of energy.
After the implementation of the above energy-saving measures, the energy consumption of the forging plant has been significantly reduced, and the energy utilization rate has been significantly improved. At the same time, due to the adoption of advanced equipment and control technology, the yield of the factory has also been greatly improved, which has brought considerable economic and social benefits for the enterprise.
Iv. Conclusion
This paper analyzes the current situation and existing problems of energy consumption in forging production, introduces feasible energy-saving technology, and further expounds the importance and feasibility of energy-saving technology through case analysis. The results show that energy saving technology can effectively reduce the energy consumption and improve the energy utilization rate in the forging production process, and bring considerable economic and social benefits to enterprises.
In the future, with the continuous improvement of environmental awareness and the rise of energy costs, energy-saving technology will be more and more widely used in the forging production process. Therefore, forging production enterprises should actively introduce advanced energy-saving technology and equipment, strengthen energy-saving management and technical research, in order to improve the competitiveness of enterprises and achieve sustainable development.
