How to determine the technological plan when forging
How to determine the technological plan when forging
The purpose of forging process economic analysis is to explore the best technical solutions and pursue the greatest economic effect. Any production process must not only formulate the process, determine the process parameters and process equipment, but also discuss the economic effects.
The principle of determining the forging process is to consume the least amount of labor and create the most material wealth. The optimization of the process is to seek the minimum value in the total consumption of materials, equipment, energy and labor on the premise of ensuring product quality and quantity. For the forging process. It can be specifically: crane wheel forgings have high dimensional accuracy, organization and performance meet requirements; low raw material consumption, small equipment investment, simple tools, low energy consumption, low labor intensity, and no pollution to the environment.
How to determine the technological plan when forging crane wheel forgings?
Technical and economic effects are carried out by the comparative method. When comparing process schemes, there may be more than two schemes. In order to make the conclusion of the analysis correct and reliable, the exhaustive method should be used to list possible schemes or alternative schemes. To this end, it is necessary to conduct forging process analysis, explore a variety of processes and plans, and prepare conditions for technical and economic analysis and selecting the best process plan. The general process analysis tasks can be summarized as follows: according to the functional characteristics, material, shape, dimensional accuracy, quality requirements and production batch of crane wheel forgings, the existing or available equipment, devices, tools, energy, inspection methods, management level Under the condition of the quality of personnel, various process plans are available.
In the process analysis, the following questions must be considered and answered: whether it can meet the function of the part; whether it can meet the technical conditions and quality standards of the drawing; whether the structure of the crane wheel forging is reasonable and whether there is excess dressing; whether the machining allowance can be reduced ; Whether the deformation force or deformation function is reduced; whether the metal flow line meets the requirements; whether the processes to ensure quality are omitted; whether the processes and work steps have been minimized; whether the material utilization is sufficient, is it possible to forge with other crane wheel forgings, one die Multiple pieces or multiple pieces in one bill; have you considered advanced techniques such as cold forging, precision forging, rolling, partial die forging, segmented die forging, combined die forging, forging and welding.
Process analysis steps. The process analysis takes specific crane wheel forgings as the object, comprehensively uses the metal pressure processing principles, forging technology, metallurgy and heat treatment, forging equipment and automation, and other discipline knowledge and factory production practices, starting from analyzing the function and technical requirements of crane wheel forgings To explore various possible deformation methods and design a reasonable crane wheel forging structure. Determine the appropriate machining allowances, tolerances and process dressings, and draw the crane wheel forgings. Calculate the force required for deformation according to the shape and deformation method of the crane wheel forging, select the main forging equipment, determine the heating temperature according to the material and deformation method of the crane wheel forging, and select the heating method and heating equipment. Choose the blanking equipment according to the type of forging equipment, deformation method and blank size. Determine the process route according to the quality requirements of the crane wheel forgings, and select equipment such as trimming, correction, precision pressing, heat treatment, cleaning, inspection, and flaw detection. Determine the production cycle and productivity according to the production batch, and then calculate the number of equipment. Calculate various consumption data according to equipment performance characteristics and productivity, such as consumption of materials, power, blanking, auxiliary materials and molds. According to the selected process, consider the production organization, equipment characteristics, determine the plant area required for production and the number of production workers, auxiliary workers, technical and management personnel. Then analyze the advantages and disadvantages of various processes, such as: labor conditions, environmental protection and the needs of technology and labor skills.
Before drawing an alternative process plan, it is necessary to screen and eliminate the technically unreliable process. The so-called unreliable process includes the following aspects: unable to complete the forming of crane wheel forgings; dimensional accuracy does not meet the requirements of drawings; metal flow lines are unreasonable or cannot meet the requirements of crane wheel forgings on metal flow lines; cannot meet crane wheels Performance requirements such as strength, stiffness and hardness of forgings; can not meet the quality tolerance and dimensional tolerance requirements of crane wheel forgings or subsequent processing; can not obtain the required design or mold, can not get the necessary power, fuel, raw materials, auxiliary materials Supply; serious public hazards or damage to the health of the operator but unable to prevent or obtain due preventive measures, etc.
After the above analysis and comparison process, we have a comprehensive understanding of the processing method of specific crane wheel forgings. If the analysis is based on existing knowledge and experience, the proposed several process solutions will be limited to existing production methods, on this basis, further thinking and proposing new ideas. In view of the inherent shortcomings of the existing schemes, in the case of the possibility of deformation methods, reduction of procedures, energy saving, and material saving, the crane wheel forgings are improved or changed to conceive new technological schemes. The new idea has to go through the above procedures, calculate various technical data, and form a complete process plan.
Process analysis is a system engineering problem. Although it is still an analogy and inference on the basis of experience so far, it is a method characterized by the personal mental work of the technologist. Therefore, the person engaged in this work is required to be familiar with the existing production methods and master the characteristics and application of various process schemes. Scope and restrictions. It can accurately calculate various technical parameters, understand the current status, trends and development trends of forging production at home and abroad, and can infer and predict according to actual conditions.