The process of forging steel flanges generally consists of the following processes, that is, selecting high-quality steel billets for blanking, heating, forming, and cooling after forging. The process methods of forging steel flanges include free forging, die forging, and film forging. During production, different forging methods are selected according to the quality of forgings and the number of production batches.
Free forging has low productivity and a large machining allowance, but the tools are simple and versatile, so it is widely used for forging single-piece and small-batch forgings with relatively simple shapes. Free forging equipment includes air hammers, steam-air hammers, hydraulic presses, etc., which are suitable for the production of small, medium, and large forgings. Die forging has high productivity, simple operation, and easy mechanization and automation. Die forgings have high dimensional accuracy, a small machining allowance, and a more reasonable fiber structure distribution of forgings, which can further improve the service life of parts.
The basic process of free forging: during free forging, the shape of the forging is gradually forged from the blank through some basic deformation processes. The basic processes of free forging include upsetting, drawing, punching, bending, and cutting.
1. Upsetting Upsetting is an operation process in which the original billet is forged in the axial direction to reduce its height and increase its cross-section. This process is often used for forging gear blanks and other disc-shaped forgings. Upsetting is divided into two types: total upsetting and partial forging.
2. Elongation Elongation is a forging process that increases the length of the blank and reduces the cross-section. It is usually used to produce shaft blanks, such as lathe spindles and connecting rods.
3. Punching is a forging process in which a punch is used to punch out a through hole or a non-through hole on the blank.
4. Bending is a forging process in which the blank is bent into a certain angle or shape.
5. Twisting is a forging process in which one part of the blank is rotated at a certain angle relative to another part.
6. The forging process of cutting and dividing the billet or cutting off the head.