Defects and Countermeasures of Large-scale Forging Parts
Abstract
Large-scale forging parts play an important role in modern industrial production, but they are also prone to various defects, such as organizational non-uniformity, surface quality problems, uneven shrinkage and cracks. This paper will discuss the causes, forms and countermeasures of the above defects, so as to provide guidance for the production and control of large-scale forging parts.
Keywords: Forging parts; Organizational non-uniformity; Surface quality; Shrinkage; Crack
1 Introduction
With the rapid development of modern society, large-scale forging products have been widely used in industrial production and daily life. At present, there are many kinds of forging products, such as turbine blade, big bracket, compressor blade, transmission pressure plate, connecting rod, etc. These products require higher processing accuracy, which often cause defects in production, such as appearance, organization, surface quality and shrinkage. Therefore, it is important to find out the causes of the defects of large-scale forging parts, study their forms and countermeasures, and establish a scientific and effective quality control system to improve product quality.
2 Defects of large-scale forging parts
2.1 Organizational non-uniformity
The organizational non-uniformity of large-scale forming parts is caused by the unreasonable process parameters, insufficient technological means, improper materials and unreasonable forging process, resulting in uneven grain structure change, shape and size change, excessive or insufficient heat treatment or quenching and tempering, or uneven surface plastic deformation of the parts. The organizational non-uniformity results in unreasonable mechanical properties and limits the fatigue strength of the parts under dynamic load.
2.2 Surface quality problems
The surface quality problems of large-scale forging parts are mainly caused by incomplete filling, uneven filling strength and process control is not accurate. The surface quality problems include rough surface, surface collapse, uneven hardness and internal force of the parts. These defects can reduce the surface precision and performance stability of the parts, as well as affect the aesthetics of the parts.
2.3 Uneven shrinkage and cracks
The uneven shrinkage and cracks of large-scale forging parts are caused by the improper stresses of the production process. The uneven shrinkage and the cracks can reduce the stiffness, reliability and strength of the parts, and even cause the parts to lose their function.
3 Countermeasures for large-scale forging parts
3.1 Modify process parameters
The process parameters of large-scale forging parts should be adjusted in time according to product design requirements and process characteristics. The process parameters should be optimized constantly to make the organization of parts consistent, and the precision and surface quality of parts should meet the requirements.
3.2 Improve equipment
It is necessary to improve the forging equipment, which can reduce the errors caused by the equipment itself and ensure the good process effect. Improving the equipment performance can also improve the surface quality, organization and size accuracy of the parts.
3.3 Material selection
The selection of materials must be based on product design requirements and process conditions. The quality of raw materials should be controlled, and the harmful impurities of materials should be screened out. The selection of materials must be considered from the aspects of cost, performance and safety.
3.4 Rational choice of heat treatment
The heat treatment process is an important factor affecting the quality of large-scale forgings. Reasonable heat treatment process can ensure that the mechanical properties and surface quality of the parts meet the requirements. Heat treatment parameters should be adjusted regularly to avoid excessive or insufficient heat treatment, which can cause uneven organization and shrinkage.
4 Conclusion
Large-scale forging parts have certain defects in production process. By analyzing the causes, forms and countermeasures of the defects, the production and quality control of large-scale forging parts can be improved, and a scientific and effective quality control system can be established.
