Forging Parts, in simple terms, are metal products with specific shapes and sizes formed by plastic deformation of metal billets under external pressure according to the forging process. During forging, the forging machine applies pressure to the metal billet to make its shape and size what people want. This process not only changes the appearance of the metal, but more importantly, it optimizes the grain structure inside the metal. It is like rearranging a group of disorderly people in order, so that the mechanical properties of the metal such as strength, toughness and fatigue life can be improved.
When forging free Forging Parts, the metal billet is placed between the upper and lower anvils, and then impact or pressure is applied to it to deform it. Its biggest feature is that the shape of the forging is mainly shaped by the forging worker's skills and is basically not limited by the mold. This forging method is very flexible and can create a variety of Forging Parts, whether they are strange in shape or large in size. Large parts such as large ship crankshafts and turbine main shafts are often manufactured by free forging. Because these parts are large and complex in shape, free forging can better meet their special requirements. However, free forgings also have shortcomings. Their dimensional accuracy is not very high, and the surface is not as smooth as die forgings. This is because it is mainly operated manually, and it is difficult to control the size and surface quality as accurately as the die.
For example, to forge a simple shaft-type free Forging Parts. First, you have to select a suitable metal blank according to the requirements of the shaft, and then heat it to the specified forging temperature. Next, place the heated blank on the anvil. The forger uses a sledgehammer or a press to apply pressure to the blank, allowing it to slowly lengthen in the axial direction. During this process, the worker must constantly turn the blank over to ensure that all parts of it can be deformed evenly and finally form the basic shape of the shaft. When forging, the worker must rely on his own experience to judge the deformation of each place, so as to ensure the quality of the forging.
The manufacturing process of die forgings is to place the metal blank in a forging die with a specific shape, and then use a press and other equipment to apply pressure to deform the blank in the die, and finally obtain a forging with the same shape as the die. Die forging has many advantages, including high production efficiency, high dimensional accuracy of forgings, good surface quality, and the ability to forge parts with complex shapes. For example, parts such as connecting rods and gears in automobile engines are suitable for manufacturing by die forging because automobile production requires a large number of these parts and their dimensional accuracy and shape consistency are very high. However, die forging also has disadvantages. It requires special molds, and the design, manufacturing and maintenance costs of molds are very high. Moreover, die forging is only suitable for mass production. If it is a single piece or small batch production, the cost is too high and it is not cost-effective.
Take the die forging of automobile connecting rods as an example. First, a pair of upper and lower forging dies should be designed and manufactured according to the shape and size of the connecting rod. The shape of the die cavity should match the final appearance of the connecting rod. Then, the heated metal blank is placed in the lower die cavity. Next, a press is used to move the upper die downward to apply pressure to the blank. The blank is subjected to pressure from all directions in the die cavity, and it will slowly fill up all parts of the die cavity, and finally become a connecting rod forging that is the same as the die cavity. The entire process is carried out within the constraints of the mold, so the dimensional accuracy and shape accuracy of the connecting rod can be well guaranteed.
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