WHAT DO YOU KNOW ABOUT THE PRODUCTION PROCESS OF FLANGES?

For the processing and production of flanges, the use of new process technologies and methods can reduce production costs, save energy and improve material utilization. The processing of the flange mainly includes the following process.

 

1. Casting Flange Processing

The selected raw material steel is smelted in a medium frequency electric furnace to make the molten steel temperature reach 1600-1700℃. The metal mold is preheated to 800-900℃ to maintain the constant temperature. Then the centrifuge is started, the molten steel is injected into the preheated metal mold. The castings are naturally cooled to 800-900℃ to keep for 1-10 minutes, and the castings are removed by cooling with water close to normal temperature.

 

2. Forging Flange Processing

The forging process generally consists of the following steps: selecting high-quality billet blanking, heating, forming, and cooling. The forging process is flat-die forging, stamp forging and film forging. At the time of production, different forging methods are selected according to the quality of the forgings and the number of production batches. If the forgings have higher dimensional accuracy, smaller machining allowance, and the fiber structure distribution of the forgings is more reasonable, it can further improve the service life of the parts.

(1) For flat-die forging, the shape of the forging is gradually forged by some basic deformation process.

1) Upsetting is an operation in which the raw material is forged in the axial direction to reduce its height and increase the cross section. This procedure is commonly used for forging gear blanks and other disc-shaped forgings. The ups and downs are divided into two types: all upsetting and partial forging.

2) Drawing is a forging process that increases the length of blank and decreases the cross section. It is usually used to produce axle blanks, such as lathe spindle and connecting rod.

3) Punching refers to the forging process in which a punch is used to punch through-hole on the blank.

4) Bending refers to the forging process in which billets are bent to a certain angle or shape.

5) Torsion refers to the forging process in which one part of the blank rotates at a certain angle relative to the other part.

6) Cutting refers to the forging process of cutting blank or cutting blank head.

 

(2) The stamp forging is formed by placing the heated billet in the forging die fixed on the die forging equipment.

1) The process of stamp forging: cutting, heating, pre-forging, final-forging, punching, trimming, quenching and tempering, shot peening. Commonly used processes are upsetting, lengthening, bending, punching, and forming.

2) Common stamp forging equipment includes stamp forging hammer, hot stamp forging press, flat forging machine and friction press.

 

3. Cutting Flange

On the middle plate, the disk with the inner diameter and the inner diameter of the flange with the processing amount is directly cut out, and the bolt hole and the water line are processed. The flange that produced by this way is called a cutting flange. The maximum diameter of such a flange is limited to the width of the middle plate.

 

 

4. Rolling Flange

The process of cutting strips with medium plates and rolling them into circles is called rolling, which is mostly used in the production of some large flanges. After the rolling is successful, the welding is carried out, and then the flattening is performed, finally the process of the water line and the bolt hole is processed.

 

Generally speaking, the quality of forged flange is better such as blind flange, slip on flanges, threaded flange, plate flange and so on. It is usually produced by stamp forging. The crystal structure is fine and the strength is high. Of course, the price is more expensive.