Classification of Defects of Die-Forging for Liquid Model
Liquid Model Die-Forging is a common manufacturing process for obtaining components with high strength, good surface quality and fine detailed performance. It is also applicable for processing materials with complicated structure and complicated shape. Die-forging is an economical and effective means of forming various kinds of metallic components. Nevertheless, in this manufacturing process, some defects are likely to occur. According to the survey, the types of defects and their causes in the die-forging process could be classified into four main categories: 1) Defects caused by improper die design; 2) Defects caused by improper material selection; 3) Defects caused by poor process selection; 4) Defects caused by incorrect process method.
The first kind of defects, those caused by improper die design, can range from simple issues such as flat or angular defects to more complicated features like drafts, springbacks or edge effects. These issues arise when the die geometry and dimensions do not match the part dimensions and shape. This can be avoided by proper design of the die before manufacturing.
The second type of defects is those caused by improper material selection. This happens when incorrect material grades, hardnesses or microstructures are selected for the part. Different materials present different properties, and thus their suitability should be given special attention. Failure to do so can result in irregular fitting parts, difficult and time consuming machining or even defects leading to product failure.
The third type of defects is those caused by poor process selection. These result when insufficient or improper knowledge and experience is applied to the selection of the best process for the application. This can result in inefficient and uneconomical methods of die-forging.
The last type of defects is those associated with incorrect process method. Examples of these include inadequate forming pressures, too slow or fast force application, improper lubricant application, etc. Taking these into account, the pressure and position can be accurately calculated and optimized to form the best quality parts.
In conclusion, the defects present in die-forgings may have various causes, ranging from improper die design to incorrect process method. Hence, sufficient knowledge and experience of die-forging isan important criterion for effectively avoiding these defects. The use of suitable materials and correct selection of process and formulation parameters all become critical in obtaining operationally reliable forging parts with high quality. Furthermore, performing regular inspections and applying suitable corrective measures can help prevent manufacturing defects and promote product quality.
By understanding the possible causes of defects, manufacturers and industries can employ effective methods to reduce the potential of die-forging defects. By doing so, they can minimize their costs, increase productivity and manufacture parts of superior quality.
