Let's learn more about the production process of forged flanges:
The forging process generally consists of the following steps: selecting the steel billet for cutting, heating, forming, and cooling after forging. The forging process methods include free forging, die forging, and membrane forging. During production, different forging methods are selected based on the quality of the forgings and the number of production batches.
Free forging has low productivity and large machining allowance, but the tool is simple and versatile, so it is widely used for forging single piece and small batch forgings with simpler shapes. Free forging equipment includes air hammers, steam air hammers, and hydraulic presses, which are respectively suitable for the production of small, medium, and large forgings. Die forging has high productivity, simple operation, and is easy to achieve mechanization and automation. The dimensional accuracy of die forgings is high, the machining allowance is small, and the fiber structure distribution of forgings is more reasonable, which can further improve the service life of parts.
1
The basic process of free forging: During free forging, the shape of the forging is gradually forged into the billet through some basic deformation processes. The basic processes of free forging include upsetting, elongation, punching, bending, and cutting.
1. Upsetting is the process of forging the raw material along the axial direction to reduce its height and increase its cross-section. This process is commonly used for forging gear blanks and other disc-shaped forgings. Upsetting is divided into two types: full forging and partial forging.
2. Drawing is a forging process that increases the length of the billet and reduces the cross-section. It is usually used to produce shaft blanks, such as lathe spindles, connecting rods, etc.
3. Punching is a forging process where a punch is used to punch through or through holes in the blank.
4. Bending is a forging process that bends the billet into a certain angle or shape.
5. Twisting is a forging process that causes one part of the billet to rotate at a certain angle relative to the other.
6. The forging process of cutting and dividing billets or cutting off material heads.
II
Die forging
The full name of die forging is model forging, which is formed by placing the heated billet in a forging die fixed on the die forging equipment.
1. The basic process of die forging: cutting, heating, pre forging, final forging, punching and connecting, trimming, tempering, and shot peening. Common processes include upsetting, elongation, bending, punching, and forming.
2. Common forging equipment includes forging hammers, hot forging presses, flat forging machines, and friction presses.
Simply put, forged flanges have better quality and are generally produced through die forging. They have a fine crystal structure and high strength, but of course, they are also more expensive.
Both cast and forged flanges are commonly used manufacturing methods for flanges. Depending on the strength requirements of the components to be used, if the requirements are not high, turning flanges can also be chosen.
3、 Cutting flange
Directly cut the inner and outer diameters and thickness of the flange on the middle plate, and then proceed with the processing of bolt holes and water lines. The flange produced in this way is called a cut flange, and the large diameter of this type of flange is limited to the width of the middle plate.
4、 Rolled flange
The process of using a medium plate to cut strips and then roll them into a circle is called coiling, and is often used in the production of some large flanges. After successful rolling, welding is carried out, then flattening is carried out, followed by the processing of water lines and bolt holes.
