The purpose of economic analysis of forging process is to explore the best technical scheme and pursue the maximum economic effect. In any production process, it is not only necessary to formulate the process, determine the process parameters and process equipment, but also to discuss the economic effect.
The principle to determine forging process is to create the most material wealth with the least labor consumption. Process optimization is to minimize the total consumption of materials, equipment, energy and labor on the premise of ensuring product quality and quantity. For forging process, it can be specifically as follows: the forging has high dimensional accuracy, and its structure and properties meet the requirements; Low raw material consumption, small equipment investment, simple tools, low energy consumption, low labor intensity, and no environmental pollution.
The effect of technological economy is carried out by comparison. When comparing process schemes, there may be more than two schemes. In order to make the analysis conclusion correct, the method of enumeration shall be used to list possible schemes or alternative schemes. Therefore, it is necessary to conduct forging process analysis, explore multiple processes and schemes, and prepare conditions for technical and economic analysis and selection of the best process scheme. The task of general process analysis can be summarized as: to propose various process schemes for use under the conditions of existing or available equipment, devices, tools, energy, inspection means, management level and personnel quality according to the functional characteristics, material, shape, dimensional accuracy, quality requirements and production batch of parts.
Some problems must be considered in process analysis.
Consider whether the functions of parts can be met; Whether the technical conditions of drawings and quality standards can be met; Whether the structure of forgings is reasonable and whether there are surplus materials; Whether the machining allowance can be reduced; Whether the deformation force or deformation work can be reduced; Whether the metal flow line meets the requirements; Whether the quality assurance process is omitted; Whether the processes and steps have been minimized; Whether the materials are fully utilized, whether it is possible to forge with other parts, and whether there are many parts in one the first mock examination or one blank; Whether cold forging, precision forging, rolling, local die forging, sectional die forging, combined die forging, forging welding and other advanced processes are considered.
According to the shape, size and deformation mode of forgings, calculate the force required for deformation, and select the main forging equipment. The heating temperature shall be determined according to the forging material and deformation mode, and the heating mode and equipment shall be selected. The blanking equipment shall be selected according to the forging equipment type, deformation mode and blank size. Determine the process route according to the quality requirements of forgings, and select equipment such as trimming, correction, forging, heat treatment, cleaning, inspection, flaw detection, etc. Determine the production rhythm and productivity according to the production batch, and then calculate the equipment data. According to the performance characteristics and productivity of the equipment, calculate various consumption data, such as the consumption of materials, power, blanking, auxiliary materials and molds.
According to the selected process, considering the production organization and equipment characteristics, determine the plant area required for production and the number of production workers, auxiliary workers, technical and management personnel Then analyze the advantages and disadvantages of various processes, such as: labor conditions, environmental protection and the demand for technology and labor skills.
Process analysis is a system engineering problem. Although the analogy and inference are still based on experience up to now, and are characterized by personal mental work of technologists, it is required that those engaged in this work should be familiar with the existing production methods and master the characteristics, scope of application and limitations of various process schemes. Can correctly calculate various technical parameters, understand the current situation, trend and development trend of forging production at home and abroad, and can infer and predict according to actual conditions.