What are the common production defects of crankshaft forgings and their prevention measures?

Crankshaft forging is one of the key parts of automobile engine, which is prone to some production defects in the manufacturing process. These defects will not only affect the performance and life of the engine, but also may endanger driving safety. Therefore, the importance of preventing production defects of crankshaft forgings is self-evident.

1. Production defects

Shape defects Shape defects refer to the geometric shape deviations that occur in the manufacturing process of crankshaft forgings, such as distortion, bending, cracks, etc. These defects not only affect the performance of the engine, but also may cause operational failures and even safety accidents.

Uneven hardness

Hardness is one of the important performance indexes of crankshaft forgings. Uneven hardness will lead to local fatigue, wear and fracture of the crankshaft in the process of use, which seriously affects the life of the engine.

2. Preventive measures

Adjust forging process

Adjusting forging technology is an effective measure to prevent the shape defects of crankshaft forgings. Specifically, it includes optimizing the forging temperature, adjusting the mold geometry, and improving the stamping speed. Through these measures, the internal stress generated in the forging process can be reduced and the formation of shape defects can be avoided.

Optimized heating process

The heating process has an important influence on the hardness of crankshaft forgings. Optimizing the heating process ensures that the crankshaft forgings are heated evenly during the heat treatment process, thus improving the hardness uniformity. Specific measures include using high temperature charging, high temperature holding time and uniform heating.

Strengthen quality inspection

Strengthening quality inspection is an important means to prevent production defects. In the manufacturing process, the quality of crankshaft forgings should be strictly tested, including geometric size, surface quality, hardness and other indicators. For unqualified forgings, they should be reworked or scrapped in time to avoid entering the market and ensure the quality and reliability of products.

Iii. Case analysis

A crankshaft forging manufacturer encountered production defects such as shape defects and uneven hardness in the production process. To address these issues, the company has taken the following measures:

Adjust forging process

The company has optimized the forging process, improved the accuracy and life of the mold, and adopted an advanced CNC hydraulic press to control the stamping speed and the closing speed of the mold, thereby reducing the internal stress during the forging process and avoiding the formation of shape defects.

Optimized heating process

In the heat treatment process, the company adopts measures such as high temperature charging, high temperature holding time and uniform heating to ensure that the crankshaft forgings are uniformly heated during the heating process, improving the uniformity of hardness.

Strengthen quality inspection

In the forging and heat treatment process, the company has strengthened the quality inspection, using advanced measuring instruments to strictly test the geometry, surface quality and hardness of the forgings. For unqualified forgings, the company carried out rework or scrap treatment in time to ensure product quality and reliability.

Through the implementation of the above measures, the company has successfully solved the production defects of crankshaft forgings, and the product performance and quality have been significantly improved. At the same time, these measures also improve production efficiency, reduce production costs, and win a better market reputation and economic benefits for the company.