What are the requirements of forging forging production line?
2023-08-04
What are the requirements of forging forging production line?
Configuration requirements for forging waste heat quenching production line and automatic production line. Forging process is the forming process of forgings, which plays a leading role in the quality of waste heat quenching products. The forging waste heat quenching production line and automatic production line should be formed around the forging host according to the technical requirements of different forgings and production batches, so as to rationally organize production, reduce transportation, save labor, and improve the working environment.
Billet heating system: requires fast heating speed, less oxidation and decarbonization, good and stable heating quality, easy to adjust the heating rhythm temperature control and can automatically sort the unqualified billet temperature. It is suggested to use the medium frequency induction heating furnace and the temperature control system of heating temperature measurement and sorting, which can not only measure the billet temperature automatically, but also carry out automatic sorting according to the billet temperature.
Forging equipment: It should be able to meet the deformation speed, shape variable and deformation mode required by the residual heat quenching of forging, so it should be selected with the strong rhythm of production equipment, shorten the residence time after forging, and ensure that the strengthening effect of plastic deformation is inherited. So that the quality of waste heat quenching parts is good and stable.
Residual heat quenching device: it is best to install a mild temperature sorting device before the workpiece enters the quenching medium to prevent the workpiece below the quenching temperature from mixing, of course, if the forging heating temperature, final forging temperature and production rhythm can be strictly controlled, it may not be installed.
In order to avoid quenching workpiece accumulation caused by quenching quality instability, the workpiece to keep moving in the quenching medium, so the quenching device is often used conveyor belt or hanging chain, and can adjust the moving speed to ensure the necessary cooling time. The appropriate method should be selected according to different forgings and yields. In order to improve the cooling capacity of the system and achieve the purpose of uniform cooling, the medium mixing and spraying device should be set in the quenching tank.
No matter what kind of quenching medium, the use temperature should be stable in a certain range, and a large amount of heat brought into the quenching workpiece must be quickly taken away by the heat exchange cooling device. This is also an important factor affecting the quality of heat treatment, so it can not be ignored in the design. Multiple plate heat exchangers are often used for medium heat exchange, external circulation of water as the medium, and outdoor cooling towers are built; If water is used as the quenching medium, the heat exchanger can be omitted; Advanced air coolers are also available. In addition, it is necessary to install a heater, when the quenching medium temperature is too low due to various factors and the quenching medium is stopped, the quenching medium is automatically heated.
The best solution of the quenching cooling system is to form a closed-loop control system and an automatic control system by the quenching medium temperature measuring device, heater, heat exchanger, cooling water system and cooling water electric control valve. According to the temperature of the quenching medium, the flow of the cooling water is automatically adjusted to ensure that the temperature of the quenching medium can be stabilized in a small range, avoid the defect of manual control of the temperature fluctuation of the quenching medium, and ensure the quality of the residual heat quenching of the forging.
Tempering equipment: Its production capacity should be matched with the production capacity of forging equipment and quenching beat. The tempering equipment is placed after the waste heat quenching device, and a forging continuous production line is formed with the quenching system. The tempering furnace can also be set separately and placed in the heat treatment workshop. This should be determined according to the forging equipment production arrangement, such as forging equipment is three consecutive production, you can consider forming a continuous production line.
If the forging equipment is produced in two shifts, the tempering furnace should be set separately, because the energy consumption of the heat treatment equipment is the lowest in three shifts of continuous production, and the energy consumption of intermittent production will increase (the heat treatment furnace must be insulated when the forging equipment stops production), the tempering furnace wastes energy in the waiting process, and the energy saving effect is greatly reduced. Therefore, considering the factors such as forging equipment failure and mold change and mold adjustment in the forging process, if the metallographic structure and mechanical properties of the forging allow, the tempering furnace can be set separately to implement the centralized tempering treatment of the forging, so that the energy waste is smaller.
Regardless of whether the tempering furnace is set on the forging continuous production line or the tempering furnace is set separately, in order to reduce the risk of cracking of the forgings after quenching, the quenched workpiece should be tempered as soon as possible. The time that can be placed after quenching is related to the forging material, quenching cooling method, forging shape and temperature, and needs to be determined according to the test.
Configuration requirements for forging waste heat quenching production line and automatic production line. Forging process is the forming process of forgings, which plays a leading role in the quality of waste heat quenching products. The forging waste heat quenching production line and automatic production line should be formed around the forging host according to the technical requirements of different forgings and production batches, so as to rationally organize production, reduce transportation, save labor, and improve the working environment.
Billet heating system: requires fast heating speed, less oxidation and decarbonization, good and stable heating quality, easy to adjust the heating rhythm temperature control and can automatically sort the unqualified billet temperature. It is suggested to use the medium frequency induction heating furnace and the temperature control system of heating temperature measurement and sorting, which can not only measure the billet temperature automatically, but also carry out automatic sorting according to the billet temperature.
Forging equipment: It should be able to meet the deformation speed, shape variable and deformation mode required by the residual heat quenching of forging, so it should be selected with the strong rhythm of production equipment, shorten the residence time after forging, and ensure that the strengthening effect of plastic deformation is inherited. So that the quality of waste heat quenching parts is good and stable.
Residual heat quenching device: it is best to install a mild temperature sorting device before the workpiece enters the quenching medium to prevent the workpiece below the quenching temperature from mixing, of course, if the forging heating temperature, final forging temperature and production rhythm can be strictly controlled, it may not be installed.
In order to avoid quenching workpiece accumulation caused by quenching quality instability, the workpiece to keep moving in the quenching medium, so the quenching device is often used conveyor belt or hanging chain, and can adjust the moving speed to ensure the necessary cooling time. The appropriate method should be selected according to different forgings and yields. In order to improve the cooling capacity of the system and achieve the purpose of uniform cooling, the medium mixing and spraying device should be set in the quenching tank.
No matter what kind of quenching medium, the use temperature should be stable in a certain range, and a large amount of heat brought into the quenching workpiece must be quickly taken away by the heat exchange cooling device. This is also an important factor affecting the quality of heat treatment, so it can not be ignored in the design. Multiple plate heat exchangers are often used for medium heat exchange, external circulation of water as the medium, and outdoor cooling towers are built; If water is used as the quenching medium, the heat exchanger can be omitted; Advanced air coolers are also available. In addition, it is necessary to install a heater, when the quenching medium temperature is too low due to various factors and the quenching medium is stopped, the quenching medium is automatically heated.
The best solution of the quenching cooling system is to form a closed-loop control system and an automatic control system by the quenching medium temperature measuring device, heater, heat exchanger, cooling water system and cooling water electric control valve. According to the temperature of the quenching medium, the flow of the cooling water is automatically adjusted to ensure that the temperature of the quenching medium can be stabilized in a small range, avoid the defect of manual control of the temperature fluctuation of the quenching medium, and ensure the quality of the residual heat quenching of the forging.
Tempering equipment: Its production capacity should be matched with the production capacity of forging equipment and quenching beat. The tempering equipment is placed after the waste heat quenching device, and a forging continuous production line is formed with the quenching system. The tempering furnace can also be set separately and placed in the heat treatment workshop. This should be determined according to the forging equipment production arrangement, such as forging equipment is three consecutive production, you can consider forming a continuous production line.
If the forging equipment is produced in two shifts, the tempering furnace should be set separately, because the energy consumption of the heat treatment equipment is the lowest in three shifts of continuous production, and the energy consumption of intermittent production will increase (the heat treatment furnace must be insulated when the forging equipment stops production), the tempering furnace wastes energy in the waiting process, and the energy saving effect is greatly reduced. Therefore, considering the factors such as forging equipment failure and mold change and mold adjustment in the forging process, if the metallographic structure and mechanical properties of the forging allow, the tempering furnace can be set separately to implement the centralized tempering treatment of the forging, so that the energy waste is smaller.
Regardless of whether the tempering furnace is set on the forging continuous production line or the tempering furnace is set separately, in order to reduce the risk of cracking of the forgings after quenching, the quenched workpiece should be tempered as soon as possible. The time that can be placed after quenching is related to the forging material, quenching cooling method, forging shape and temperature, and needs to be determined according to the test.
Environmental protection and safety devices: whether it is a newly designed forging waste heat production line or a reformed forging waste heat production line of an old forging unit, it is necessary to consider the emission and recovery of oil and smoke, and do a good job of safety protection for operators. Therefore, the quenching tank should be closed and have an air extraction device. It is best to use a closed cleaning machine to clean the quenched forgings and then temper them. Other processes of forging production, such as the following materials, finishing, flaw detection, etc., should be considered according to their necessity whether to be included in the production line, when the load is less than 50%, generally should not be included in the production line.
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