Advanced technology and production and testing equipment play an important role in ensuring the feasibility and stability of the forging process, and improving the quality and stability of forgings, especially high-speed and heavy-duty gear forgings. Luo Baihui, secretary general of the International Mould Association, said that my country has a complete set of advanced production equipment from forging, heat treatment, machining to flaw detection, including a program-controlled temperature-controlled natural gas heating furnace with independent intellectual property rights, and an ultrasonic C-scan flaw detector. And other equipment are at the international leading level.
　　 High-speed and heavy-duty gear forgings are the key and basic parts of transmission equipment. Their stress conditions are complex and working conditions are special. Therefore, they must have excellent working performance to ensure long-term, efficient, safe and stable operation of gear transmission equipment. The performance, quality and stability of high-speed and heavy-duty gear forgings are closely related to the forging process. According to Luo Baihui, secretary general of the International Mould Association, in terms of patented technology, my country's Jiangsu Jinyuan has 3 invention patents such as multi-point temperature sensing and intelligent control methods for gas heating furnaces and detachable molds for rounding shaft forgings8 A utility model patent, gas heating furnace temperature uniformity control technology, precision forging technology, successive control deformation technology, warm forming structure performance control technology, ultrasonic C-scan automatic detection technology for forging defects, 5 proprietary technologies, and exclusive license Use 1 invention patent.

It is reported that Jiangsu Jinyuan has long focused on the R&D, production and sales of high-speed and heavy-duty gear forgings. It has accumulated rich experience in process control in the production and operation process, gathered and trained a large number of professional and technical personnel, and formed a series of proprietary technologies. .

Jinyuan Forging currently has an annual output of 60,000 tons of forgings. Its products are widely used in equipment manufacturing industries such as electric power, motor cars, ships, metallurgy, port machinery, and heavy machinery. It has covered more than 20 provinces and cities across the country, and some products are exported to the Netherlands, Canada, the United States, India, Japan, Spain, Germany and other international markets. The product has stable quality and high reliability, and has been praised by users at home and abroad. It has been awarded the honorary titles of excellent supplier and best supplier by customers many times.

　　In the modern forging process, for the shaft forgings, the shaft forgings are generally rounded and rough processed by the plastic mold (throwing). Rounding is to realize the shaping of the circular cross-section of shaft forgings. The existing molds used for rounding are likely to cause mold damage or material loss. In addition, the flexibility of the mold is not enough. Once damaged, the entirety must be disassembled and replaced, which is time-consuming and labor-intensive.

Jinyuan Forging has optimized the tooling die for shaft forgings and developed a modular forging die for shaft forgings, which facilitates the replacement of the arc shaping modules of the main working parts, saves materials and time, and improves efficiency. Different arc-shaped shaping modules can also be adapted to different working environments. For example, the invented composite tire mold for complex shaft forgings with shoulders and flanges can adapt to different lengths, steps, and shafts with flanges. Forging of forgings. In addition, it can effectively reduce the probability of mold damage, because when the shaft forgings with larger diameters are used, it often appears in the contact part of the upper and lower molds (upper and lower dies). Under impact extrusion, sharp corners are formed. After an impact cycle is over, the shaft forgings will rotate. The sharp corners formed will damage the mold or break away from the shaft forgings under impact. The detachable mold containing the rotating module for the round shaft forging can reduce the possibility of sharp corners on the shaft forging, protect the mold, and save materials.

　　Through continuous technological innovation, my country's current forging production efficiency and energy-saving level are close to the level of forging power Japan. Jiangsu Jinyuan has also become the pioneer of technological innovation in the domestic forging industry, especially high-speed and heavy-duty gear forging manufacturers.

In October 2020, the crude steel output of 64 countries included in the World Steel Association statistics was 161.9 million tons, an increase of 7.0% year-on-year. Due to the ongoing impact of the new crown epidemic, many production data released this month are estimates. We may revise the data in the production report next month.

In Asia, China’s crude steel output in October was 92.2 million tons, an increase of 12.7% year-on-year; India’s crude steel output in October was 9.1 million tons, an increase of 0.9% year-on-year; Japan’s crude steel output in October was 7.2 million tons, a year-on-year increase A decrease of 11.7%; South Korea’s crude steel production in October was 5.9 million tons, a year-on-year decrease of 1.8%.

In the EU, Germany’s crude steel production in October was 3.4 million tons, an increase of 3.1% year-on-year; Italy’s crude steel production in October was 2.1 million tons, a year-on-year decrease of 4.6%; Spain’s crude steel production in October was 1.1 million tons, a year-on-year increase A decrease of 7.7%.

In North America, the crude steel production in the United States in October was 6.1 million tons, a year-on-year decrease of 15.3%.

In the CIS region, the estimated crude steel output in October 2020 is 8.4 million tons, an increase of 4.7% year-on-year. Among them, Ukraine's crude steel output in October was 1.7 million tons, an increase of 5.9% year-on-year.

In other European countries, Turkey’s crude steel output in October was 3.2 million tons, an increase of 19.4% year-on-year.

In South America, Brazil’s crude steel output in October was 2.8 million tons, an increase of 3.5% year-on-year.

Recently, the cadres and employees of Longgang Steel Company of Shaanxi Iron and Steel Group followed the goal of "reducing system cost by another 100 yuan", used their brains, actively explored practice, and innovatively developed a new baking device for blast furnace slag skimmer, and successfully applied it in production .

　　The blast furnace taphole is an important part of the blast furnace ironmaking system. Its function is to separate the slag and iron, lead the molten iron into the molten iron tank, and lead the slag into the slag treatment and crushing device. In actual production, when the blast furnace is pouring new iron ditch, in order to ensure the later life of the iron ditch, the newly poured iron ditch must be baked before it can be used. However, since the baking operation of this unit used the baking method in which the skimmer well was inserted into the homemade baking tube, it not only took more than 12 hours for continuous baking, but the baking tube could not enter the inside of the skimmer, which easily caused iron trough baking. Uneven baking results in a significant shortening of the service life of the new iron groove.

　　 In response, the company established a technical research team, after careful research, finally developed a new baking device for blast furnace slag skimmer. This set of equipment not only shortens the baking time to 8 hours, but also enables the newly cast iron ditch to be put into use 3 hours earlier, and the skimmer bakes evenly, which further guarantees the casting quality of the iron ditch.

Actually, the surface of the imitation tool is distributed, the size of the micro-convex body is unequal, and the surface of the imitation tool is unequal, and the surface of the imitation tool is a micro-convex body. Under the condition of free lubrication, the work is basically done on the surface of the imitation tool. For this purpose, the lubricant is lubricated, the fluid is lubricated, the fluid is lubricated, and the fluid is lubricated.

Medium friction (secondary) main finger metal shavings or work giving upper and lower imitation friction, polishing main measure research imitation polishing. Metal-thermal friction science Special conquest, thermal, comparative metal hair, or work temperature comparison low (phase-to-heat metal), metal-hard metal model, phase-to-slip (metal flow) friction, in fact, contact surface Friction secondary; Under non-lubricating conditions, hardened imitation tool, two kinds of metal surface oxidized film, contact friction; during the process of transformation, the surface of the new metal, the surface of the new metal, the short time, and the return Under the conditions of oxidation, maximum absorption of the metal, maximum load, or high temperature, the friction and friction are insufficient, and the approximate rate of work is large. The universal existence of heat, uneven shape, poor lubrication or poor lubrication. In addition to this, forging load forging, normal mechanical load, cause of mechanical load, sub-phase ratio, forging process, unique friction science special conquest.

At present, in order to make use of the waste heat of large forgings, after forging, the heat of the parts is directly used for heat treatment. There are generally three types of forging waste heat heat treatment. Next, I will explain these three types in detail:

(1) After forging heat treatment of forging parts: that is, the forging parts are directly subjected to heat treatment after forging, which closely combines forging and heat treatment. This process is also called high temperature deformation heat treatment. After forging heat treatment can save a lot of energy and man-hours, and improve labor Productivity, in addition, cross heat treatment can also make forgings to obtain good comprehensive mechanical properties. For this reason, countries all over the world adopt a large amount of post-forging waste heat treatment: that is, by controlling the forging and controlling the after forging, to prevent the formation of coarse ferrite and pearlite as well as the precipitation of two-shaped carbides, so that it can directly obtain the equivalent of forging again. The structure and performance of conventional normalizing, isothermal normalizing and quenching performed by heating. In this way, conventional normalizing, equal overflow E hardening and reheating of quenching can be cancelled.

 (2) After forging heat treatment of forged parts: that is, the forging parts after forging are directly sent to the average temperature heat treatment process, and the heat treatment process is still performed according to the conventional forging heat treatment process. This method is called waste heat homogenization heat treatment, such as a PSH type 63MN electric The screw press forging automatic production line is equipped with an automatic quenching and tempering line of a 270kW suspension temperature quenching electric furnace. If the residual heat of the forging is not used, it is necessary to be equipped with a 1000kW quenching resistance heating furnace to produce light vehicle crankshafts and front axles .

(3) Then use part of the waste heat for heat treatment: that is, after inlaying waste heat quenching, after forging, both through waste heat quenching, after forging waste heat normalizing and after forging waste heat isothermal normalizing, the grain size of forgings is larger than conventional heat treatment, which is refined The grain can cool the forging to 600C~650C, and then heat the forging to the required temperature for quenching (normalizing) for quenching (normalizing), which can refine the grain and save the forging from room temperature to 600C. ~650C energy consumption, generally used for forgings with high grain size requirements, which can save about 60% of energy

Forging refers to a workpiece or blank obtained by forging and deforming a metal blank. By applying pressure to the metal blank, it produces plastic deformation, which can change its mechanical properties. According to the temperature of the blank during processing, forgings can be divided into cold forging and warm forging and hot forging. Cold forging is generally processed at room temperature, and hot forging is processed at a temperature higher than the recrystallization temperature of the metal blank.
The preparation before forging includes raw material selection, calculation, blanking, heating, calculation of deformation force, selection of equipment, and design of molds. It is necessary to choose a good lubrication method and lubricant before forging.
Forging materials involve a wide range, including steel and high-temperature alloys of various grades, as well as non-ferrous metals such as aluminum, magnesium, titanium, copper, etc.; there are both bars and profiles processed into different sizes at one time, and a variety of Ingots with specifications; in addition to using a large number of domestic materials suitable for my country's resources, there are also materials from abroad.

Forging

Most of the forged materials are listed in national standards, and many are new materials developed, tried and promoted. As we all know, the quality of products is often closely related to the quality of raw materials. Therefore, for forging workers, they must have the necessary material knowledge and be good at selecting the most suitable materials according to the process requirements.

Material calculation and blanking are one of the important links to improve material utilization and realize blank refinement. Too much material not only causes waste, but also aggravates cavity wear and energy consumption. If the blanking does not leave a margin, it will increase the difficulty of process adjustment and increase the scrap rate. In addition, the quality of the blanking end face also has an impact on the process and the quality of cylindrical forgings.
The purpose of heating is to reduce forging deformation force and improve metal plasticity. But heating also brings a series of problems, such as oxidation, decarburization, overheating and overburning. Accurate control of the initial forging and final forging temperature has a great influence on the product structure and performance. Flame furnace heating has the advantages of low cost and strong applicability. However, the heating time is long, oxidation and decarburization are prone to occur, and the working conditions need to be continuously improved. Electric induction heating has the advantages of rapid heating and less oxidation, but it has poor adaptability to product shape, size and material changes.
Forging forming is produced under the action of external force. Therefore, correct calculation of deformation force is the basis for selecting equipment and checking mold. The stress and strain analysis inside the deformed body is also indispensable for optimizing the process and controlling the structure and performance of the forging.
There are four main methods for analyzing deformation force. Although the principal stress method is not very strict, it is relatively simple and intuitive. It can calculate the total pressure and the stress distribution on the contact surface of the workpiece and the tool. The slip line method is strict for the plane strain problem. It is relatively intuitive to solve the stress distribution for the local deformation of high parts, but the scope of application is narrow.

Forging

The upper limit method can give an overestimated load, and the upper limit element can also predict the shape change of the workpiece during deformation. The finite element method can not only give the external load and the change of the workpiece shape, but also the internal stress and strain distribution. The disadvantage is that the computer time is more, especially when the elastoplastic finite element is used to solve the problem, the computer capacity is larger. The machine time is longer. Recently, there is a trend to adopt a joint method to analyze problems, for example. The upper limit method is used for rough calculation, and the finite element is used for detailed calculation in key parts.

Reducing friction can not only save energy, but also increase the die life of forgings. Since the deformation is relatively uniform, it helps to improve the structure and performance of the product. One of the important measures to reduce friction is to use lubrication. Due to the different forging methods and the difference in working temperature, the lubricants used are also different. Glass lubricants are mostly used for forging of high-temperature alloys and titanium alloys. For hot forging of steel, water-based graphite is a widely used lubricant. For cold forging, due to the high pressure, phosphate or oxalate treatment is often required before forging.