Forging is one of the important processes in the field of metal forming, which is widely used in many industries such as automobile, aviation and energy. In the forging process, the metal will produce plastic deformation when subjected to external forces, forming the desired shape and size. However, the problems such as uneven deformation and residual stress that may occur in the deformation process not only affect the dimensional accuracy and surface quality of the forging, but also reduce its mechanical properties and service life. Therefore, effective control and optimization of deformation in forging process is the key to improve forging quality and reduce production cost.
Deformation causes in forging processing
Material properties: The yield strength, plasticity, elastic modulus and other performance parameters of the material have an important effect on the deformation behavior. The deformation behavior and sensitivity of different materials are different.
Forging process parameters: forging temperature, forging speed, forging force and other process parameters directly affect the flow and deformation behavior of the metal. Improper setting of process parameters may lead to uneven deformation and residual stress.
Mold design: The structure, size, material and other factors of the mold will affect the flow and distribution of the metal, thus affecting the deformation behavior of the forging.
External factors: such as lubrication conditions, ambient temperature and other external factors will also affect the deformation behavior of the forging.
Deformation control strategy
Material selection and pretreatment: According to the requirements of the forging and process characteristics, select the appropriate metal materials, and carry out the necessary pretreatment, such as heat treatment, surface cleaning, etc., in order to improve the plasticity of the material and reduce deformation sensitivity.
Optimization of process parameters: Through the test and simulation analysis, determine the best forging temperature, forging speed, forging force and other process parameters. Reasonable process parameters can ensure uniform metal flow and reduce residual stress.
Mold design and improvement: Optimize the structure and size of the mold to ensure the accuracy and stability of the mold. The use of advanced mold materials and manufacturing technology to improve the durability and wear resistance of the mold. In addition, the lubrication system and cooling system of the mold are reasonably designed to reduce the influence of friction and heat on deformation.
Deformation prediction and compensation: Using numerical simulation technology, the deformation behavior of forging is predicted and analyzed. According to the predicted results, the necessary compensation design of the mold is carried out to offset the influence of deformation. At the same time, through real-time monitoring and feedback control, the deformation in the forging process can be adjusted and optimized in time.
Deformation optimization strategy
Introduction of advanced forging technology: The use of isothermal forging, superplastic forging and other advanced technology to improve the flow and formability of metal. These techniques can reduce uneven deformation and residual stress, improve dimensional accuracy and surface quality of forgings.
Implement multi-pass forging: The forging process is broken down into multiple passes to gradually change the shape and size of the metal. Multi-pass forging can reduce the deformation of metal, reduce the residual stress and improve the forming quality of forging.
Optimized lubrication conditions: Suitable lubricants and lubrication methods are used to reduce friction and heat generation between the metal and the mold. Good lubrication conditions can reduce the deformation resistance of the metal and improve the durability of the mold.
Implement heat treatment and post-treatment: Heat treatment or post-treatment of forged forgings, such as annealing, normalizing, etc., to eliminate residual stress and improve the mechanical properties of the material. These post-treatment measures can further improve the quality and service life of forgings.
Deformation control and optimization in forging process is an important means to improve forging quality and reduce production cost. The deformation behavior of forgings can be controlled effectively through reasonable selection of materials, optimization of process parameters, design and improvement of dies, deformation prediction and compensation. At the same time, the introduction of advanced forging technology, the implementation of multi-pass forging, the optimization of lubrication conditions, heat treatment and post-treatment measures can further optimize the deformation behavior of the forging, improve the quality and performance of the forging. In the future development, with the continuous progress and innovation of technology, it is believed that the deformation control and optimization strategy in forging processing will be more perfect and efficient.
