The production process of cast flanges. The casting process generally consists of the following processes: selecting high-quality steel billets for cutting, heating, forming, and cooling after forging. The casting process methods include free forging, die forging, and membrane forging. During production, different casting methods are selected based on the size of the forging quality and the number of batches produced.
Free forging has a low production rate and large machining allowance, but it is simple in both east and west and has great universality, so it is widely used for casting single pieces with relatively simple shapes and small batch forgings. Free forging equipment includes air hammers, steam air hammers, and hydraulic presses, which are suitable for the production of small, medium, and large forgings, respectively. Die forging has a high production rate, simple operation, and simple completion of mechanization and automation. The dimensional accuracy of die forgings is high, the machining allowance is small, and the fiber structure distribution of forgings is more reasonable.
The fundamental process of free forging: During free casting, the shape of the forging is gradually forged into the billet through some fundamental deformation processes. The fundamental processes of free casting include upsetting, elongation, punching, bending, and blocking. The full name of die forging is model casting, which involves casting the heated billet into a forging die fixed to the die forging equipment.
The fundamental process of die forging: cutting, heating, pre forging, final forging, punching, edge cutting, tempering, and shot peening. Common processes include upsetting, elongation, bending, punching, and forming. Commonly used die forging equipment includes die forging hammers, hot die forging presses, flat forging machines, and friction presses.
Simply put, the quality of cast flanges is better, usually produced through die forging, with fine crystal structure and high strength. Of course, the price is also higher. Both cast and cast flanges belong to the commonly used manufacturing methods for flanges. Depending on the strength requirements of the components to be used, if the requirements are not high, turning flanges can also be chosen.
Cut flange. Directly cut the inner and outer diameter and thickness of the flange on the middle plate with machining allowance, and then proceed with the processing of bolt holes and water lines. The flange produced in this way is called a cut flange, and the maximum diameter of this type of flange is limited to the width of the middle plate. Roll flange. The process of using a medium plate to cut strips and then roll them into a circle is called rolling, and is often used in the production of some large flanges. After successful rolling, welding is carried out, and then flattening is carried out, followed by the processing of water lines and bolt holes.