The quality of forging technology will directly affect the performance adaptation of bearings. Therefore, many people have many questions about bearing forging technology. For example, what are the problems with forging technology of small and medium-sized bearings? What is the impact of forging quality on bearing performance? Which aspects are reflected in the upgrade of bearing forging technology? Let’s give you a detailed answer.

The current problems in the forging technology of small and medium-sized bearings mainly include:

(1) Due to the long-term influence of the industry’s “reliance on cold and less hot” thinking, the cultural level of employees in the forging industry is generally low: coupled with the poor working conditions and working environment, they think that as long as they have strength, they do not realize that forging is a special process. Its quality has a major impact on bearing life.

(2) The scale of enterprises engaged in bearing forging is generally small, and the level of forging technology is uneven, and many small and medium-sized enterprises are still at the stage of forging control.

(3) Forging companies have generally improved the heating method and adopted intermediate frequency induction heating, but they only stayed at the stage of heating only the steel rods. They did not realize the importance of heating quality, and the industry did not have an intermediate frequency induction forging industry. Technical specifications, there is a great quality risk.

(4) Process equipment mostly uses press connection: manual operation, human factors have a great influence, poor quality consistency, such as forging and folding, size dispersion, fillet lack of material, overheating, overburning, wet cracking, etc.

(5) Due to the difficult working environment of forging and processing, young people are unwilling to engage in it. Difficulties in recruiting are a common problem in the industry. Forging enterprises are even more difficult, which poses a great challenge to forging automation and information upgrading.

(6) The production efficiency is low, the processing cost is high, the enterprise is in a low-level ecosystem, and the living environment is deteriorating.

What are the effects of forging quality on bearing performance?

(1) Network carbide, grain size and streamline of forgings: affect the fatigue life of the bearing.

(2) Forging cracks, overheating, and overburning: seriously affect the reliability of the bearing.

(3) Forging size and geometric accuracy: affect the automation of turning processing and material utilization.

(4) Production efficiency and automation: Affect the manufacturing cost and quality consistency of forgings.

Which aspects are reflected in the upgrade of bearing forging technology? This is mainly reflected in two aspects.

one is the upgrade of material technology, and the other is the transformation of forging automation.

Material technology transformation and upgrading; standard upgrading: mainly reflected in the following aspects.

(1) Smelting process: vacuum smelting.

(2) Increased the control of trace harmful residual elements: from 5 to 12.

(3) The key indicators of oxygen, titanium content, and DS inclusion control approach or reach the international advanced level.

(4) Significant improvement in uniformity: Segregation of main components significantly improves the application of controlled rolling and controlled cooling process, controlling rolling temperature and cooling method, realizing double refinement (refining austenite grains and carbide particles), and improving carbide network level.

(5) The qualified rate of carbide strips is significantly improved: the casting superheat is controlled, the rolling ratio is increased, and the high temperature diffusion annealing time is guaranteed.

(6) Improved consistency of bearing steel quality: The pass rate of physical metallurgical quality heats has been greatly improved.

Forging automation transformation:

1. High-speed forging. Automatic heating, automatic cutting, automatic transfer by manipulator, automatic forming, automatic punching and separation, realizing rapid forging, speed up to 180 times/min, suitable for forging of large quantities of small and medium bearings and auto parts: the advantages of high-speed forging process are reflected In the following aspects.

1) Efficient. High degree of automation and high production efficiency.

2) High quality. Forgings have high machining accuracy, less machining allowance, and less waste of raw materials; forgings have good internal quality and streamlined distribution is conducive to enhancing impact toughness and wear resistance, and bearing life can be more than doubled.

3) Automatic material throwing at the head and tail: remove the blind area and end burrs of the bar inspection.

4) Energy saving. Compared with conventional forging, it can save energy by 10%~15%, save raw materials by 10%~20%, and save water resources by 95%.

5) Security. The entire forging process is completed in a closed state; the production process is easy to control, and it is not easy to produce water quenching cracks, mixing and overburning.

6) Environmental protection. There are no three wastes, the environment is clean and the noise is less than 80dB; the cooling water is used in closed circulation, basically achieving zero discharge.

2. Multi-station walking beam. Using hot die forging equipment: complete the pressing, forming, separating, punching and other processes on the same equipment, and the walking beam is used for the transfer between the processes, which is suitable for medium-sized bearing forging: production cycle 10-15 times/min.

3. Robots replace humans. According to the forging process, multiple presses are connected: the product transfer between the presses adopts robot transfer: suitable for medium and large bearings or gear blank forging: production cycle 4-8 times/mino

4. Manipulators replace humans. Renovate the existing forging connection, use simple manipulators to replace people in some stations, simple operation, low investment, and suitable for automatic transformation of small enterprises.