Forging Process Optimization: Methods To Improve Material Utilization Efficiency

Forging, as the core process of mechanical manufacturing, is widely used in fields such as automobiles, aviation, and engineering machinery. However, its traditional process suffers from serious material waste and excessive scraps. Optimizing forging process and improving material utilization can not only reduce production costs but also reduce resource consumption, achieving efficient and green production. The following introduces core optimization methods based on practical points.

1、 Optimize billet design (source reduction)

Blank design is the foundation for improving material utilization, with the core being "precise matching and reducing redundancy". Abandoning traditional uniform specification billets, customized billets are used based on the size and shape of forgings, and the volume of billets is accurately calculated to avoid excessive corner materials caused by oversized billets. At the same time, using nearly net shaped billets, through precise cutting and upsetting pretreatment, the shape of the billet is made to approach the final forging, reducing the subsequent forging processing allowance and reducing material waste from the source. Generally, the material utilization rate can be improved by 10% -15%.

2、 Improve forging process parameters (process consumption reduction)

Optimize core parameters such as forging temperature, deformation speed, and reduction amount to reduce material loss. Reasonably control the heating temperature to avoid material oxidation and burning caused by overheating, while ensuring good plasticity of the material and reducing problems such as cracking and excessive flash during the forging process. Adopting multi pass progressive forging instead of traditional single pass large deformation forging, accurately controlling the deformation amount of each pass, reducing the flash width and thickness, and reducing material loss during the trimming process. In addition, isothermal forging technology is adopted to improve the forming accuracy of forgings and reduce subsequent machining allowances.

3、 Introducing advanced forging technology (technology efficiency improvement)

Maximizing material utilization through advanced technology. Promote precision forging technology, such as cold temperature precision forging and powder forging, to achieve near net shape production of forgings, significantly reduce machining allowances, and even eliminate the need for machining. The material utilization rate can be increased to over 85%. Using numerical simulation technology to simulate the forging process in advance, optimize mold design and process path, and avoid material waste and forging scrap caused by unreasonable processes. At the same time, the introduction of automated cutting and sorting equipment reduces manual operation errors and improves the utilization rate of raw materials.

4、 Recycling of scraps and process control (closed-loop efficiency improvement)

Establish a mechanism for recycling and reusing scrap materials, classify and collect the flying edges and scrap materials generated during the forging process, and after remelting and tempering treatment, use them as raw materials for production again, achieving material recycling. At the same time, strengthen production process control, standardize operating procedures, reduce scrap of forgings caused by operational errors, and reduce material loss. Regularly maintain and calibrate forging equipment to ensure accuracy and avoid material waste caused by equipment failures.

The optimization of forging process needs to be combined with multiple aspects such as billet, parameters, technology, and control. It can effectively improve material utilization, reduce production costs, and enhance the quality of forgings, promoting the development of the forging industry towards high efficiency, green, and energy-saving.