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Forged Shaft Manufacturing Process
Forged shaft is one of the indispensable parts in modern industry, which can work in the environment of high strength, high temperature, large load and torque. The forged shaft manufacturing process is relatively complicated. It is a high-strength forging manufacturing technology, so it has high requirements for production technology, production equipment and materials. So, how are forged shafts made? What technologies are needed for its forging process? What factors need to be considered?
The forged shaft manufacturing process mainly includes material selection, preheating, forging, heat treatment, machining, surface treatment and other links.
1. Material Selection
Before manufacturing shaft forgings, the selection of materials is very important. It is necessary to select high-quality steel as raw materials according to the demand for shafts to ensure the durability, wear resistance and various mechanical properties of shaft forgings.
2.Preheating
Preheating is one of the indispensable links in the forged shaft manufacturing process and plays an important role. Put the cleaned raw materials into the furnace for preheating, so that the temperature reaches the required temperature uniformly. Different types of shafts have different preheating times, for example: fan shaft forgings, the first preheating is 800°C, the second preheating is 500-650°C and 850°C; the gear shaft needs to be heated to 950°C ℃ or so. The final preheating temperature and time depend on the performance and material requirements of the forged shaft. The main purpose of the preheating process is to reduce the internal stress of the material, improve the deformation capacity, improve the plasticity of the metal, improve the forging efficiency and quality, and ensure the forming quality and performance of the forged parts.
3.Forging
The forging process of shaft forging is a high-strength forging manufacturing technology, and it is also the most important link in the forged shaft manufacturing process. After the material is taken out of the preheating furnace, it is cooled to a temperature range suitable for forging to avoid hot cracking or hot embrittlement, and then forging is carried out. The traditional forging process of forging shaft includes cold forging and hot forging. Cold forging can strengthen the metal, improve the surface quality, and maintain the hardness and strength of the material. The process is generally processed at room temperature; the hot forging process is processed at a temperature higher than the recrystallization temperature of the blank metal, and the temperature is higher than 800 ° C, that is Forging at high temperature, using this process, can reduce the deformation resistance of the metal and improve the plasticity and toughness of the material.
The forging process in the forging shaft manufacturing process adopts different methods according to different requirements, such as free forging, rotary forging, closed test die forging, radial forging, closed test upsetting forging and so on. Forging is the deformation of the material under the action of external force. At every moment of forging deformation, the internal tensile stress should be avoided or reduced, and the occurrence of two-way tensile stress should be eliminated. Therefore, the deformation force should be calculated correctly, and the forging strength,time and temperature should be controlled.
Through the forging process, the shaft forging can obtain the required shape and size, and can also eliminate the as-cast looseness and welding holes of the metal. This process is also the most critical process in the forged shaft manufacturing process.
4. Heat Treatment Process
The heat treatment process is carried out after forging, and is also a necessary link in the forged shaft manufacturing process. The heat treatment process mainly includes two processes: heating and cooling. The forged shaft is heated, and after reaching a certain temperature, it is cooled. The heat treatment of the forged shaft can eliminate the stress generated in the forging process and improve the structure and performance of the shaft.
5. Machining Process
Machining is an important process in the manufacturing process of forged shafts, including turning, grinding, milling, drilling, EDM, etc. Machining processes can make the shaft forgings meet the precision requirements and ensure the surface quality.
6.Surface Treatment Process
This process is the last step in the forged shaft manufacturing process, including grinding, polishing, sandblasting, spraying, etc. The specific selection process is based on customer requirements. The purpose of surface treatment is to remove impurities such as oxides, rust, and burrs on the surface of the shaft forgings to make the surface smooth and flat, and at the same time improve the corrosion resistance and aesthetics of the shaft forgings.
There are different types of forged shaft, and the materials used are also different, so the forged shaft manufacturing process used will also be different. For the forging of shafts, the technology of these manufacturing processes is related to the quality and performance of shaft forgings, so continuous optimization of these manufacturing processes can produce better forged shafts.