Precision Forging Process Flow

Precision forging, compared to traditional forging, aims for higher dimensional accuracy and material utilization. Taking a 6-inch flange as an example, the process flow typically includes the following steps:

Material Preparation: Select high-quality steel billets (such as carbon steel, stainless steel, or Hastelloy), choosing the appropriate material based on the flanges operating environment (such as high temperature, high pressure) to ensure strength and corrosion resistance.

Heating: Heat the billet to around 1150℃ to improve plasticity and reduce deformation resistance. The heating temperature must be strictly controlled to avoid overheating or scale formation.

Multi-Station Forging:

Upsetting: Remove scale and initially shape the billet, controlling the height-to-diameter ratio between 1.5-2.5 to ensure stable positioning.

Pre-Forging: Initially form the part using open dies, distributing the metal material to avoid insufficient filling or excessive flash during final forging.

Final Forging: Precision forge using closed dies, with a machining allowance of only 1-2mm, reducing subsequent machining.

Punching and Trimming: Punch out through holes (such as the center hole of a 6-inch flange) and trim excess flash.

Cooling and Heat Treatment: Control the cooling rate (such as air cooling or pit cooling), and improve mechanical properties through heat treatments such as quenching and tempering.

Surface Treatment and Inspection: Sandblasting and pickling ensure surface quality, and strict inspection of dimensions, hardness, and defects (such as porosity and cracks).