To improve the utilization rate of forging cutting materials, it is necessary to make three-dimensional efforts from \"optimization design, process improvement and fine control\". The core is to reduce waste production and maximize the use of billet. The specific methods are as follows:
Accurate matching of billet size: according to the final shape and processing allowance of the forging, combined with the forging shrinkage rate, the optimal billet size is calculated through simulation (such as Deform software) to avoid \"overqualified use\".
Cutting and combination cutting: multiple continuous cutting is used for rod material (such as cutting multiple small blanks in turn), and flat plate billet adopts typesetting optimization software to plan the cutting path to reduce corner waste.
Special-shaped billet replaces cylindrical billet: for complex forgings (such as valve body and fork parts), the special-shaped billet after extrusion and upsetting is used to reduce the metal loss in subsequent forging and reduce the processing allowance.
Select high-precision cutting equipment: CNC sawing machine, laser cutting, plasma cutting and other equipment, replace the traditional grinding wheel saw, reduce the incision loss (the accuracy can be improved to less than ± 0.5mm, the incision width can be reduced by 30%).
Promotion of uncut cutting technology: the hot shear, cold shear or high-speed cutting process is used for the rod material to avoid the cutting waste produced by saw, especially suitable for small and medium parts in mass production.
Optimize the pre-cutting pretreatment: straighten and surface clean the raw materials to reduce the cutting deviation and increase of waste materials caused by material bending and corrosion.
Strictly control the quality of raw materials: avoid the inclusion, shrinkage hole and other defects, and reduce the scrap and material waste caused by unqualified billet.
Establish billet traceability and reuse mechanism: the remaining materials after unloading should be classified and marked (material, specification, margin), and preferentially used for small forgings or repair parts to realize the reuse of surplus materials.
Optimize the forging process to reduce the loss: through uniform heating and reasonable control of forging temperature, reduce the oxidation burning loss and decarburization layer thickness; optimize the mold design, reduce the amount of flying edge, and ensure the full forging.
Adopt ERP or MES system: real-time management of raw material inventory, cutting plan and residual material status, accurately match production demand and avoid blind feeding.
Introduce AI optimization typesetting: automatically generate the optimal material typesetting scheme through artificial intelligence algorithm, dynamically adjust the setting strategy to adapt to the production needs of different batches and specifications.