Analysis and Improvement of Production Process Technology for Engineering Machinery Gear Forgings

With the continuous development of the engineering machinery industry, gear forgings, as important transmission components, have been widely used. However, there are still many problems in the production process, such as thermal cracking and deformation, so it is necessary to conduct process analysis and improvement to improve production efficiency and product quality.

I. Process analysis

1. Raw material selection: High-quality steel with low carbon content and impurities such as sulfur and phosphorus should be selected as raw materials to minimize any negative impact.
2. Heating method: Adopt uniform heating to avoid local overheating or overcooling, which may cause negative effects.
3. Forging temperature control: Reasonable forging temperature should be selected according to different types of steel and section sizes to ensure easy plastic deformation and prevent deformation, thermal cracking, and other phenomena.
4. Forging pressure control: Different forging pressures should be selected according to the shape, size, and material of the casting to prevent deformation, longitudinal cracking, cutting, and other phenomena caused by excessive or insufficient pressure.
5. Cooling method control: As the steel has excellent ductility at high temperature, correct cooling methods should be used during forging to gradually harden the metal material, thereby preventing distortion or deformation of the casting.
6. Heat treatment: According to the size and shape of the forging obtained after forging, a reasonable heat treatment process should be selected to improve the microstructure and physical and mechanical properties of the steel.

II. Process Improvement

1. Improve heating method: Use newer and more precise CNC electrode cutting technology to prepare insulation hood bodies, increase the heating power of the heater, achieve more uniform heating effects, and reduce the negative impact caused by local temperature anomalies.
2. Optimize forging process: Improve mold design, forging parameter selection, cooling methods, etc. to avoid mold sinking and bending, improve size accuracy and mechanical properties, and use positive and negative dislocation forging and preforming forging processes as much as possible.
3. Heat treatment improvement: Improve the production process of heating, heat preservation, quenching, and tempering, pay attention to defects in the microstructure, predict and deal with post-forming and other tissue changes.
4. Improve quality inspection system: Establish a complete quality inspection system to strictly control the product’s outgoing quality. Adjust and improve problems found during the production process in a timely manner.

In summary, the production process of gear forgings involves multiple links, and good control and improvement are required from multiple aspects to ensure product quality, improve production efficiency, and better apply to fields such as engineering machinery.