How to solve the forming accuracy and metal loss problems of automobile forgings? Please provide an article and give an actual production case for illustration.
During the production process of automobile forgings, forming accuracy and metal loss are two common problems. Let’s explore how to solve these problems and analyze them with actual production cases.
I. Forming Accuracy Problem
The forming accuracy is mainly affected by the mold and process. When the mold structure is designed improperly or has been used for a long time, it will cause mold deformation, wear or excessive clearance, thereby affecting the forming accuracy of the forging. The unreasonable process parameters will also affect the forming accuracy.
To solve the forming accuracy problem, we can start from the following aspects:
- Choose the mold reasonably: the mold should have high strength and stiffness, and pay attention to maintaining the surface finish to ensure the accuracy of the forging.
- Optimize process parameters: determine reasonable forging temperature, amount of material remaining, pressure and other parameters through experiments according to the shape, size, material and other conditions of the forging, to maximize the accuracy of forming.
- Strengthen equipment maintenance: regularly clean and maintain the mold to ensure its stable performance; regularly inspect the hammer, bearing and other equipment to ensure their normal operation.
Here is an actual production case:
A company produces a batch of automotive parts forgings, which are in the shape of a complex geometry and have large dimensions. The mold used before has been used for a long time, and the hammer and press also have some faults. In order to improve the forming accuracy, the company took the following steps:
- Redesign the mold: redesign the mold structure according to the actual situation, and use high-strength and high-hardness materials for manufacturing, while paying attention to the control of machining and heat treatment process.
- Optimize process parameters: determine reasonable forging temperature, amount of material remaining, pressure and other parameters through experiments, and reasonably arrange the forging process route according to the shape and size of the forging.
- Strengthen equipment maintenance: regularly clean and maintain the mold, and carry out maintenance and replacement of key components on the hammer and press.
After the above measures, the company successfully solved the problem of forming accuracy and ensured the quality of the forging.
II. Metal Loss Problem
Metal loss refers to the appearance of pores and defects on the surface or inside of the forging due to factors such as pressure, temperature during the production process, resulting in metal waste.
The following are several methods to solve the problem of metal loss:
- Optimize mold design: avoid internal fractures during forging process as much as possible, and adopt a reasonable filling method and exhaust method to reduce the occurrence of pores, defects and other issues.
- Control forging process parameters: according to the material, shape, size and other characteristics of different forgings, control process parameters such as pressure, temperature, etc., and effectively reduce the phenomenon of metal loss.
- Strengthen experiment and research: explore the best forging process parameters and scheme through experiments and simulation analysis.
Here is an actual production case:
A company produces a batch of narrow nose impact drill bits forgings, because the forging has high complexity, many surface pores, and internal defects occurred before. In order to solve the problem of metal loss, the company took the following steps:
- Improve mold design: redesign the mold and adopt a brand new filling and exhaust method while enlarging the diameter of the mold waste outlet.
- Optimize process parameters: determine the best forging temperature, amount of material remaining, pressure and other parameters through experiments, and strictly control the forging speed and time.
- Strengthen quality inspection: strengthen the inspection during the forging production process, and timely find and deal with problems.
After adopting the above measures, the company successfully solved the problem of metal loss, and achieved efficient production.
