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Liquid die forging defects and prevention: surface adhesion and granular overflow
Die forging is a widely used process for fabricating parts with a complex shape. It is used to produce parts with a precise shape, as metal is forced into a predefined shape under extreme pressure. Like any processing method, die forging has some potential issues, chief among them being surface adhesion and granular overflow.
Surface adhesion occurs when the material being forged adheres to the form or tool used in the forging process. This can occur due to various factors, including high temperature, tight contact between the tool and the material, and the type of lubricant used. The issue is further compounded if the forging conditions are not correctly calibrated. Such circumstances can result in inadequate lubrication, premature sticking, and cold welding.
To prevent surface adhesion, it is necessary to reduce the temperature of the material and ensure the correct amount of lubricant is in contact with the material being forged. In addition, it is important that the tool and the material are kept apart during the forging process. This is done by adjusting the gap between the tool and the material, as well as by using shaping tools and work-holding shapes that prevent the material from sticking to the tool at high temperatures.
Granular overflow is another issue that can occur during liquid die-forging. This happens when the material is scattered in a random pattern around the part, due to an accumulation of excess material on the surface of the part. This can be the result of poor channel design in the die, inadequate flow control, or an incorrect gap between the die and the material.
To prevent granular overflow, it is important to design the die properly and use an optimal flow control device. The device should be designed so as to ensure that the material flow is even and consistent, and the correct gap between the die and the material should be maintained. In addition, the shape of the die should be designed to ensure that it does not accumulate material on its surface.
In conclusion, liquid die forging is a great way to produce intricate shapes and parts with a precise shape. However, like any other process, there are potential issues that can arise during the forging process, most notably surface adhesion and granular overflow. To address these issues and ensure a successful forging process, it is important to ensure the correct temperatures, lubrication, and gap settings are being used, as well as proper design and flow control of the die.
