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The manufacturing process of forged flanges typically involves several key stages: selecting high-quality steel billets, cutting to size, heating, forging into shape, and controlled cooling. Based on the desired quality and production volume, either free forging or die forging techniques are employed.
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1. Free Forging
Free forging is a versatile method characterized by low production efficiency and large machining allowances. It is ideal for single or small-batch production due to its simplicity and the use of general-purpose tools. Common equipment includes:
Air hammers (for small forgings),
Steam-air hammers (for medium-sized forgings),
Hydraulic presses (for large forgings).
The main operations in free forging include:
Upsetting: Compressing the billet axially to shorten its height and enlarge its cross-section, suitable for making gear blanks and disc parts.
Drawing (or drawing-out): Stretching the billet to increase its length while reducing its cross-section, typically used for shafts.
Punching: Creating through or blind holes in the billet using a punch.
Bending: Deforming the billet into specific angles or shapes.
Twisting: Rotating one section of the billet relative to another.
Cutting: Dividing or trimming the billet as required.
2. Die Forging
Die forging, also known as model forging, involves placing a heated billet into a die cavity and forming it under pressure. This process is well-suited for mass production due to its high precision and efficiency.
The typical steps include:
Blanking, heating, pre-forging, final forging, punching, trimming, quenching and tempering, and shot blasting.
Die forging is carried out on specialized equipment such as:
Die forging hammers,
Hot die forging presses,
Flat forging machines,
Friction presses.
This method offers several advantages:
High dimensional accuracy,
Minimal material waste,
Optimized fiber structure alignment,
Enhanced mechanical strength and service life.
Comparison with Cast Flanges
Forged flanges generally outperform cast flanges in terms of mechanical properties. They feature a finer grain structure and higher overall strength, making them more reliable in critical applications. However, forged flanges are also more expensive due to the complexity and precision of the process.
When choosing between forged and cast flanges, it's important to consider the strength requirements of the application. For non-critical or low-stress environments, machined (turned) flanges may serve as a cost-effective alternative.
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