Forgings, stampings and rolling rings
The most widely used in the production of oil and gas equipment are forged discs with a central hole, discs without a central hole, as well as rolling rings. Parts such as bottoms, collar flanges, fittings, rings, nozzles, body parts and bandages are made from this type of blanks.
Forgings are made in accordance with the requirements of GOST 8479-70, GOST 25054-81 from various grades of steel: carbon, tool and structural alloyed and others depending on the required properties of the parts that will be produced from these blanks. The weight of forgings can be practically any - from several kilograms to several tons, depending on which parts the workpiece will be used for. In terms of cross-section, all forgings are divided into square, rectangular and round forgings.
The Ring Billet Plant supplies forgings with overall characteristics:
Discs with and without holes:
- Outside diameter up to 2500 mm
- Inner diameter up to 400 mm
- Height up to 500 mm
- Weight up to 3000 kg
Rolled rings:
- Outside diameter up to 2500 mm
- Inner diameter up to 2200 mm
- Height up to 500 mm
- Weight up to 3000 kg
Forged steel grades:
- carbon steel grades 15, 20, 25, 30;
- alloy steel, manganese grades 09G2S, 10G2, 40G, 50G;
- alloy steel, chromium-silicon manganese grades 25HGSA, 30HGSA, 35HGSA, 35HM, 40HFA, 40HN;
- alloy steel, chromium-manganese grades 12Х2Н4А, 12ХН3А, 14ХГСН2МА, 18ХГТ
- alloy steel, chromium-molybdenum-vanadium grades 9X2MF, 12X1MF, 35XMFA
- alloy steel, chromium-nickel and chromium-nickel-molybdenum grades 12ХН3А, 20Х2Н4А, 20ХН3А, 30ХН3Ф, 34ХН1М,
- tool steel, stamped grades 4Х5МФС, 4Х4ВМФС, 4Х5МФ1С, 5ХНВ, 5ХНМ.
Heat treatment of the forgings provides the mechanical properties specified by the technical specifications for the forging. Heat treatment of steel forgings is annealing, normalization and quenching followed by tempering.
The Ring Billet Plant manufactures and sells a wide range of round and rectangular forgings. Here you can order forgings according to your requirements with preliminary machining.
Forgings are made from high-quality raw materials in compliance with the technology, undergo ultrasonic testing, at your request, and are supplied with quality certificates.
Flange stamping is a manufacturing method that is economically feasible and technological. It is widely used in the production of large-scale batches, characterized by a high production rate of a product of the declared quality, achieved with the use of a minimum amount of forging and pressing equipment: a hot stamping machine for upsetting and final shaping and an edging press for piercing a hole and removing flash.
When hot forging forgings of flanges for pipelines, the highest accuracy of dimensions and shape of forgings is achieved, which makes it possible to exclude subsequent machining of the outer surface of the branch pipe and the adjacent end surface of the flange part of the forging.
The main method for manufacturing flanges is considered to be hot stamping using special presses with a force of up to 4500 kN. After stamping the flanges, the process of drilling and surface treatment of the product follows on special lathes.
The ring blanks plant supplies stamped blanks of flanges in accordance with GOST 33259-2015 and GOST 12821-80 up to DN 500 mm, pressure from PN 1.6 MPa to PN 20.0 MPa from steel grades 20, 09G2S, 13XFA, 15X5M, 12X18H10T and 10X17H13M2T. Flange stamping is performed in open and closed dies, depending on the diameter and weight of the workpieces.
The finished parts are descaled and tested for mechanical properties. If necessary, ultrasonic non-destructive testing or intercrystalline corrosion resistance test can be performed.
Today, metal forming is the most common method for producing workpieces, called forgings, which are then machined to achieve the required size and configuration of the part.
Forging - the process of deformation of a metal workpiece, which is in a plastic state and giving it the desired shape by the impact of the impact load of hammer or press strikers. A distinctive feature of forging is that the workpiece is in a free position during deformation, it does not have a clear positioning.
A forging is an intermediate billet obtained by the method of plastic deformation of metal, the peculiarity of which is its similarity with the future part or product in terms of overall dimensions and shape.
The forging manufacturing process goes through the following stages:
1. Cutting of rolled products of various configurations to the required dimensions.
Used rolled products can have round, square, rectangular and polygonal sections.
2. The process of metal deformation.
3. Heat treatment of the forging (normalization and tempering)
4. Acceptance of the finished forging by the technical control department.
The allowance for machining a forged forging is almost 2 times greater than that of a forging obtained by stamping. In production, forging is used only in small-scale and one-off production by two main methods, it is manual or machine.
Stamping is the process of deformation of a metal initial workpiece under pressure, which takes place using additional equipment (a special stamp). The plastic deformation process is carried out in a die matrix, the shape of which is completely identical to the forging being manufactured. The punch acts as a striking element exerting a load.
Stamping can be performed with or without preheating the original blank.
Stamping, in contrast to forging, has a sufficiently high productivity, it does not require high qualifications of workers, and at the exit the forging has a higher dimensional accuracy and low roughness of the surface layer. However, the use of dies is advisable only in mass and serial production in order to justify the costs of their expensive production.