How to ensure process stability in forging processing?

How to ensure process stability in forging processing?

In the field of forging processing, process stability is the core factor that determines product quality, production efficiency and corporate competitiveness. Stable processes can ensure that forgings maintain consistency in terms of dimensional accuracy and mechanical properties, reduce scrap and rework rates, and reduce production costs. However, forging processing involves multiple links and multiple variables. From raw material input to finished product output, fluctuations in any link may affect process stability. In order to ensure process stability, it is necessary to work together from multiple dimensions such as raw material management, equipment maintenance, process standardization, personnel training and quality monitoring.

1. Strictly control the quality and stability of raw materials

The quality of raw materials is the basis of process stability. First, a strict supplier screening and evaluation mechanism is established, giving priority to raw material suppliers with good reputation and stable quality. During the procurement stage, raw materials such as steel and alloys are fully tested, including chemical composition analysis, mechanical property testing, and metallographic structure inspection. For example, the content of impurities such as sulfur and phosphorus in raw materials is tested through spectral analysis to ensure that they meet the process requirements and avoid hot brittleness, cold brittleness and other defects in forgings due to excessive impurities.

At the same time, we strengthen the batch management of raw materials. We mark the raw materials of the same batch, record their sources, test data and other information to ensure traceability. In the production process, we give priority to using raw materials from the same batch to avoid the process stability affected by the performance differences of raw materials from different batches. In addition, we store the raw materials properly, control the temperature and humidity environment of the warehouse, prevent oxidation and rust during the storage of raw materials, and ensure that the quality of raw materials put into production is always stable.

2. Strengthen equipment maintenance and regular calibration

The operating status of forging equipment directly affects process stability. Enterprises need to formulate a comprehensive equipment maintenance plan and regularly inspect, maintain and repair forging equipment. For example, the hydraulic system of the forging hydraulic press should regularly replace the hydraulic oil and clean the filter element to ensure the stability of the hydraulic system pressure; the temperature control system of the heating furnace should be calibrated to ensure the accuracy of the heating temperature. At the same time, establish equipment operation files to record the equipment's usage time, fault conditions, maintenance content and other information, predict potential equipment failures through data analysis, take preventive maintenance measures in advance, and reduce the impact of sudden equipment failures on process stability.

In addition, strict management is also required for tooling equipment such as molds. Molds will wear and deform during long-term use, affecting the quality of forgings. Regularly inspect molds, use 3D scanning and other technologies to monitor mold size changes, and repair or replace severely worn molds in a timely manner. At the same time, optimize the lubrication and cooling process of the mold to ensure that the mold maintains a good working condition during the production process and stabilizes the forging effect.

3. Promote process standardization and parameter solidification

Formulating detailed and unified process standards is the key to ensuring process stability. Enterprises need to compile process documents covering the entire process of raw material processing, heating process, forging operation, cooling process, etc. in combination with their own equipment conditions, production experience and industry specifications. The operating steps, process parameter range and quality control points of each process should be clarified, such as stipulating that the heating temperature of the steel ingot is 1150-1200℃, and the holding time is determined according to the size of the steel ingot, so that operators have rules to follow.

During the process execution, the key process parameters are strictly solidified. Through production tests and data analysis, the optimal range of each process parameter is determined and entered into the equipment control system. For example, in automated forging equipment, parameters such as forging pressure and deformation speed are set to fixed values to reduce parameter fluctuations caused by human operation. At the same time, a process change approval system is established. If the process parameters need to be adjusted, they must be technically demonstrated, tested and approved by relevant departments to ensure the scientificity and rationality of the process changes and prevent arbitrary changes in the process from affecting stability.

4. Strengthening personnel training and skills improvement

The skill level and work attitude of operators have a direct impact on process stability. Enterprises need to establish a complete personnel training system, carry out basic theory and practical training for new employees, so that they are familiar with forging process principles, equipment operation specifications and safety precautions; carry out regular skill improvement training for employees, invite industry experts to explain new technologies and processes, organize employees to participate in skill competitions, stimulate learning enthusiasm, and improve operational proficiency.

At the same time, the responsibilities and operating specifications of each position are clarified, and standardized operating instructions are formulated. Through regular assessment and supervision, it is ensured that operators strictly follow the specifications to implement the process and avoid process fluctuations due to improper operation. In addition, an incentive mechanism is established to link the quality of process execution with employee performance, and employees who strictly abide by process standards and have stable product quality are rewarded to increase employees' attention to process stability.

5. Improve the quality monitoring and process traceability system

Building a comprehensive quality monitoring system is an important means to timely discover process fluctuations. In the process of forging, a combination of online and offline detection is adopted. Online detection uses sensors to monitor forging temperature, pressure, deformation and other parameters in real time. Once the parameters exceed the set range, the system will immediately alarm and automatically adjust the equipment operation status; offline detection is to measure the size, hardness test, metallographic analysis and other tests of forgings after the key process to ensure that the process quality meets the requirements.

Establish a complete process traceability system to record the production process of each batch of forgings in detail, including raw material batches, process parameters, operators, test data and other information. Use the information management system to achieve real-time collection and storage of production data, so that when quality problems occur, they can be quickly traced back to specific links, analyze the causes and take improvement measures. Through continuous quality data analysis, potential process risks can be discovered, process control solutions can be optimized, and process stability can be continuously improved.

Ensuring the stability of forging processing technology is a systematic project that requires comprehensive management from multiple aspects such as raw materials, equipment, technology, personnel and quality control. By strictly controlling the key points of each link and establishing a sound management system, enterprises can effectively improve process stability, produce forging products with reliable quality, gain advantages in market competition, and promote the high-quality development of the forging processing industry.