What is the process of roll forging? Roll forging, as a kind of rotary forging, is a new process that has introduced longitudinal rolling into the forging industry in recent decades and has been developed continuously. It belongs to the category of rotary compression forming, through a pair of counter-rotating dies to apply pressure to the metal material to produce plastic deformation, so as to obtain the required forgings or forging billets. The roll forging process plays an important role in the field of metal processing because of its high efficiency, energy saving and high quality.
1. Basic principle of roll forging
The basic principle of roll forging is that through a pair of forging rollers whose axes are parallel and turn opposite, a continuous local pressure is applied to the metal material fed between them. The roll forging die, which is mounted on the forging roll and rotates with it, pulls in the longitudinal blank with the help of friction and compresses and deforms it continuously. In this process, the cross-sectional area and height of the blank compression part are reduced, the width is slightly increased, and the length is significantly extended. Roll forging deformation is a complex three-dimensional deformation, most of the material flows along the length direction to increase the length of the billet, a small part of the material flows sideways to increase the width of the billet.
Two, roll forging characteristics
High efficiency and energy saving: in the process of roll forging, the forging roll continuously rotates, the production efficiency is high, and the forming force required is smaller than the die forging, so the general selection of small capacity roll forging machine can meet the production needs. At the same time, the relative slide between the metal and the mold is less during the roll forging process, the mold wear is small, the life is long, and the production cost is further reduced.
High material utilization rate: the material utilization rate of roll forging is generally more than 80%, which is much higher than other forging methods. This is due to the continuous flow and deformation of the material during the roll forging process, which minimizes the waste of the material.
High precision: roll forging process can produce forging parts with high precision and small surface roughness. This is because the metal fiber tissue during roll forging is continuously distributed according to the profile of the forging, and is not cut off, with uniform organization and good mechanical properties. After precision roll forging, it can be directly used in production without processing.
Easy to realize automation: roll forging process is simple, no impact, vibration, etc., good working conditions, easy to realize mechanization and automatic production. In the mass roll forging production, the manipulator is widely used to transfer the workpiece, which improves the production efficiency and reduces the labor intensity.
Iii. Classification of roll forging
According to the purpose of the process and the shape of the forgings, roll forging can be divided into two types: billet roll forging and forming roll forging.
Billet roll forging: The main purpose of billet roll forging is to prepare the blank of the desired shape and size for die forging. Through continuous rolling and pressure of the roll forging machine, the original metal material is processed into an intermediate blank close to the shape of the final product for subsequent die forging processing.
Forming roll forging: Forming roll forging can directly produce forgings that meet the shape and size requirements. This process is suitable for relatively simple shape, long length of shaft parts, slabs and so on. Through continuous rolling and precise control of the roll forging machine, the metal material is gradually deformed under the action of the mold, and the desired shape of the forging is finally obtained.
4. Application of roll forging
Roll forging technology has been widely used in the field of metal processing for its unique advantages.
Automotive parts: Roll forging plays an important role in the automotive industry. For example, connecting rod, crankshaft, front axle and other auto parts can be produced by the roll forging process. These parts not only have high precision, stable quality, but also high production efficiency and relatively low cost.
Tools and farm implements: Roll forging is also widely used in the production of tools and farm implements. Such as twist drill, wrench, spike, hoe, pick, etc., these tools and farm tools vary in shape, but can be efficiently and accurately processed through the roll forging process.
Aerospace: In the aerospace sector, roll forging is used to produce critical components such as turbine blades. These parts require not only high precision and light weight, but also good mechanical properties and high temperature resistance. The roll forging process can meet these requirements and provide strong support for the development of the aerospace industry.
Other fields: In addition, roll forging process is also widely used in mining, petrochemical, weapons and other fields. These areas have different requirements for metal parts, but roller forging can meet the needs of these areas with its high efficiency, energy saving and high quality characteristics.
With its unique advantages, roll forging process plays an increasingly important role in the field of metal processing. With the progress of science and technology and the continuous optimization of process, roll forging process will be applied and popularized in more fields.
