Forged Piston for Tensioner Engine Pump
Mainly used in automotive engine tensioner systems, industrial pump systems (such as hydraulic pumps, oil pumps), etc., to maintain system tension, transmit power or pump media (such as engine oil, coolant) to ensure stable operation of mechanical systems.
classification：
Forged Parts
Keywords:
Jiesen
Product Details
1. Principle of forging process
Forging is a metal processing method that produces plastic deformation of metal blanks by applying external force (impact or pressure) to obtain parts with the required shape, size and mechanical properties. Its core principle is based on the plastic deformation characteristics of metal. By changing the internal grain structure of the metal, it eliminates casting defects (such as looseness and pores), densifies the material structure, and improves mechanical properties such as strength and toughness.
2. According to the forming method, mold type and process characteristics, forging can be divided into the following main categories:
| Process classification | Features | Application | ||||
| Open Die Forging | The blank deforms freely between simple molds (upper and lower anvils) without the need for complex molds. The forming accuracy is low, relies on operating experience, and requires subsequent cutting. Suitable for small batches and large-sized workpieces (such as shafts and rings). |
Large forgings (such as marine crankshafts, pressure vessel heads), customized parts. | ||||
| Closed Die Forging | Use special molds (forging dies) to control metal flow, with high forming accuracy and good surface quality. Pre-forging and final forging processes are required, and the mold cost is high, so it is suitable for mass production. Segmentation type: Open die forging: The mold is divided into upper and lower molds, leaving flash grooves that need to be trimmed later. Closed die forging: no or very little flash, high material utilization and higher precision. |
Automobile parts (gears, connecting rods), aerospace structural parts (turbine disk), weapon parts. | ||||
| Extrusion | The blank is extruded in the closed die cavity and flows out of the die hole to form a constant cross-section profile or pipe. It is divided into forward extrusion, reverse extrusion and composite extrusion, and is suitable for materials with good plasticity such as aluminum alloy and copper alloy. |
Door and window profiles, aviation conduits, refill tubes. | ||||
| Upsetting | By compressing the height of the blank, the diameter is increased (like bolt head forming). | Often combined with die forging, it is used for thickened parts such as gears and flanges. | ||||
| Precision Forging | Near net shape technology, the size of the parts is close to that of the finished product, reducing cutting processing and improving efficiency. | Aero engine blades. | ||||
3. The typical forging process includes the following key steps:
1. Blank preparation
Material selection: carbon steel, alloy steel, aluminum alloy, titanium alloy, etc. (need to have good plasticity).
Blanking: Calculate the quality of the blank according to the size of the forging, and use sawing, shearing or laser cutting.
2. Heating
Purpose: Reduce metal deformation resistance and improve plasticity.
Temperature control:
The forging temperature range of steel: the initial forging temperature is about 1100~1250℃, and the final forging temperature is about 800℃.
Aluminum alloy: 400~500℃; Titanium alloy: 850~950℃.
Heating equipment: electric furnace, gas furnace, induction heating furnace (suitable for large batches and rapid heating).
3. Forging and forming
Select free forging, die forging or special forging equipment (such as air hammer, hot die forging press, hydraulic press) according to the type of process.
Key parameters: deformation speed, forging force, die temperature.
4. Cooling and heat treatment
Cooling method:
Air cooling (ordinary steel), furnace cooling (high carbon steel, alloy steel, to prevent cracking), water cooling (aluminum alloy).
Heat treatment:
Annealing, normalizing, quenching and tempering, etc., eliminate forging stress, refine grains, and adjust mechanical properties.
5. Subsequent processing
Trimming, punching (forgings to remove flash), surface cleaning (shot blasting, pickling), dimensional inspection (three-coordinate measurement).
4. Materials suitable for forging process
| Material | Material characteristics | Application | ||||
| Low carbon steel (carbon content ≤0.25%) | Such as Q235, which has good plasticity and weldability | It is often used to manufacture general mechanical parts such as chains, bolts, and nuts, as well as steel sections in building structures. | ||||
| Medium carbon steel (carbon content 0.25% - 0.6%) | For example, 45 steel has high strength and hardness and good comprehensive mechanical properties. Its performance can be improved through heat treatment. | It is widely used in manufacturing gears, shafts and other mechanical parts. | ||||
| High carbon steel (carbon content＞0.6%) | Like T10 steel, it has high hardness and good wear resistance. | Commonly used in manufacturing cutting tools, measuring tools, molds, etc. | ||||
| Chromium Molybdenum Steel | It has good high temperature strength and creep resistance, as well as certain corrosion resistance. | Commonly used in the manufacture of high temperature and high pressure vessels, power station boiler pipes, etc., such as 15CrMo, 12Cr1MoV. | ||||
| stainless steel | Containing alloy elements such as chromium and nickel, it can form a dense oxide film on the surface and has excellent corrosion resistance. | According to different organizational structures and properties, it can be divided into austenitic stainless steel (such as 304, 316), martensitic stainless steel (such as 410), etc., which are widely used in food processing equipment, medical equipment, chemical equipment and other fields. | ||||
| 6061 aluminum alloy | It is an Al-Mg-Si alloy with medium strength, good plasticity and corrosion resistance, and can be strengthened through heat treatment. | Commonly used in manufacturing aerospace parts, automotive engine parts, bicycle frames, etc. | ||||
| 7075 aluminum alloy | It is an Al-Zn-Mg-Cu superhard aluminum alloy with high strength and significant heat treatment strengthening effect, but its corrosion resistance is relatively poor. | It is often used to manufacture structural parts with high strength requirements such as aircraft girders and landing gears. | ||||
| Brass | It is a copper alloy with zinc as the main alloy element. It has good mechanical properties and corrosion resistance, and the price is relatively low. | Commonly used in the manufacture of valves, pipe fittings, decorations, etc., such as H62 brass. | ||||
| Bronze | Originally refers to copper-tin alloy, now refers to copper alloys other than brass and white copper. Among them, tin bronze has high strength, wear resistance and corrosion resistance. | It is often used to manufacture bearings, gears, etc.; beryllium bronze has high strength, hardness, elastic limit and fatigue limit, as well as good conductivity and corrosion resistance. It is often used to manufacture elastic components of precision instruments, high-speed and high-pressure bearings, etc. | ||||
| Magnesium alloy | The lightest metal structural material in practical applications, it has a series of unique properties such as high specific strength and specific stiffness, good damping and machinability, and good electromagnetic shielding. | Commonly used magnesium alloys include cast magnesium alloys and deformed magnesium alloys. Cast magnesium alloys are often used to manufacture helicopter transmission system components, automobile engine hoods, etc. in the aerospace field; deformed magnesium alloys can be used to manufacture plates, pipes, bars and other products through forging, extrusion, rolling and other processes, and are used in electronic product casings, rail transit and other fields. | ||||
5. Development Trend of Jiesen Forging Technology
1. Precision and intelligence:
Promote isothermal forging and digital simulation (such as Deform, Forgemap software) to improve forming accuracy and reduce mold trial costs.
2. Green manufacturing:
Use induction heating and waste heat recovery to reduce energy consumption; develop a low-oxidation heating process to reduce surface defects.
3. Composite process integration:
Forging, welding, and heat treatment are integrated (such as forging and welding integration) to shorten the process flow.
4. Application of new materials:
Develop special forging technologies (such as superplastic forging) for difficult-to-deform materials such as titanium alloys and high-temperature alloys.
Summary
With its unique structure strengthening advantages, the forging process has become an indispensable key technology in high-end equipment manufacturing, especially in fields with high load and high reliability requirements. It is irreplaceable. With the development of digitalization and new material technology, the forging process is being upgraded in the direction of precision, intelligence, and greenness, continuing to promote the manufacturing industry towards high quality.
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