Forging and Pressing Technology: Calculation of Blank Consumption for Forgings
Forging and pressing technology is a common and essential part of many industries. It is used to form complex shapes and structures from raw metallic materials such as wrought iron, aluminum, brass, stainless steel, titanium and tool steel. Forging and pressing is an extremely precise and skilled process, one that requires an in-depth knowledge of the material, the correct tools and precise temperature control.
The initial step in forging and pressing is cutting a workpiece from raw material. The size of the workpiece, called a blank, can vary based on the desired shape and structure of the finished product. Once the blank is cut, it is heated to a precise temperature in order to prepare it for forging or pressing. As the blank is being forged or pressed, it undergoes drastic changes in its shape, size, and strength.
One of the most critical calculations in forging and pressing is the blank consumption. This is the amount of raw material, or blanks, needed to create a given quantity of finished parts. A blank consumption calculation is especially important in industries where material is expensive or difficult to come by, such as the aerospace, defense, and medical device industries. Calculating blank consumption accurately can help companies keep costs low and maintain production levels.
To calculate blank consumption, the number of parts required calls for, first of all, must be determined. If the parts fit together in a simple design, the quantity may be easy to calculate. For more complex designs, the total number of blanks needed for all pieces may need to be estimated. The size of the blank can also affect the potential loss. If a blank is too small, it can be wasted due to machining inaccuracies or small part tolerances, which can lead to more waste.
Once the quantity of parts is known, the next step is to determine the sizing and shape of the parts. For example, a standard round bar or an irregularly shaped part. In most cases, a round blank is necessary, and the diameter of the blank must coincide with the size of the finished piece. After the shape and size of the blanks have been determined, the actual calculations can begin.
The best way to calculate blank consumption is to use a formula specific to the material being used. This formula takes into account the workpiece size, geometry, compression or expansion of the material during forging or pressing, and the desired tolerance of the finished part. It is based on the internal stresses of the material and calculates the amount of raw material needed to produce each part.
When calculating blank consumption, it is also important to consider the potential for lost material due to machining errors, scrap from the machining process, and any additional material used for finishing or polishing. Additionally, the size of the blanks should be chosen carefully to minimize wasteful scrap from cutting. All of these factors should be taken into consideration when calculating blank consumption.
Forging and pressing is an essential process for many industries, and its success depends on careful calculation of blank consumption. Companies must accurately estimate their total raw material needs to ensure that they have enough blanks to make their desired number of parts. By following the above steps and formulas, companies can minimize scrap and maximize their material budgets to produce the highest quality parts.
