Forging Process Design and Process Control

Issuing time:2025-05-31 20:31Author:Timothy Forgings

Forging Process Design and Process Control

In the aerospace industry, large scale forgings involve diverse materials and processes with varying control requirements. Without classified management of these processes and clear operational guidelines, challenges such as non-standardized workflows, difficulties in process verification and improvement, recurring errors, and excessive demands on process engineers may arise. Core technical management becomes fragmented, foundational technical practices remain weak, and efficient production methods are lacking. Engineers are overwhelmed by heavy workloads, prioritizing task completion over quality, while inadequate process improvement mechanisms render continuous optimization ineffective. Thus, systematically enhancing process management and reducing operational costs are urgent priorities for enterprise development.

1. Content and Significance of Process Classification Management

· 1) Definition of Process Classification Management
As a lifecycle management system spanning from forging design to production, process management is a critical component of modern manufacturing. It applies advanced scientific theories to plan, organize, execute, control, and improve processes, ensuring adherence to established standards and procedures. Process classification management builds on this foundation, providing systematic guidance for the transformation of raw materials or semi-finished products into finished goods through scientific and structured oversight of design, technology, and process control.

· 2) Key Components of Process Classification Management
This approach analyzes forging characteristics (e.g., material formability, part geometry, production control, and client requirements) to establish tailored standards and regulations for forging design, process development, and production workflows. It ensures proper implementation of technical documents, conducts regular audits, collects innovative practices, refines processes through lessons learned, and promotes best practices to optimize cost, quality, and workflow efficiency.

· 3) Significance of Process Classification Management
By categorizing and addressing the unique requirements of different forgings, this method enhances management efficiency and quality while avoiding chaos and over-regulation. As technical management permeates the entire production cycle, process classification is integral to enterprise operations, driving consistency and coherence across all stages.

2. Objectives and Focus Areas of Process Classification Management

· 1) Goals
Enterprises aim to establish robust process classification systems, strengthen implementation of regulations and standards, refine management frameworks, and build skilled technical teams. These efforts elevate process control capabilities and ultimately enhance core competitiveness.

· 2) Key Focus Areas
Process management must align with practical enterprise needs, progressing steadily through categorization, refinement, and execution. Quality management systems should define workflows for process development and improvement, with further classification based on forging characteristics. This improves design capabilities, technical problem-solving, and integration of design, process technology, and control. Process classification is divided into three interconnected modules:

o Design Process Classification Management

o Process Technology Classification Management

o Process Control Classification Management

3. Detailed Implementation of Process Classification Management

By systematically managing design, process, and production phases, tacit knowledge held by employees is codified into written guidelines. This reduces misinterpretation from verbal communication, enables self-guided learning, and standardizes repetitive tasks and complex workflows. Key aspects include:

· 1) Design Process Classification Management
Focuses on stages such as client requirement validation, raw material analysis, technical specifications, equipment capability assessment, and forging calculations. Design documents are categorized into material property tables, equipment parameter standards, and material measurement guidelines. This streamlines design timelines, reduces labor costs, and enables flexible staffing across projects.

· 2) Process Technology Classification Management
Involves forging drawings, production plans, process specifications, technical agreements, and testing protocols. Standard templates for drawings, design principles, and technical agreements are developed to save time, improve consistency, and minimize low-level errors.

· 3) Process Control Classification Management
Covers raw material procurement, forging, heat treatment, and issue resolution. Control documents define internal procurement standards, forging requirements, metallurgical problem-solving procedures, and in-process testing protocols. These ensure operational consistency across shifts and reduce variability caused by differing skill levels.

4. Conclusion

Aerospace large-scale forgings are characterized by small batches and high diversity, demanding stringent process controls. Comprehensive implementation of process classification management is vital. Key priorities include iteratively refining classification practices, establishing scientific management systems, and enhancing enterprise competitiveness. This approach addresses the unique challenges of aerospace forging production, ensuring quality, efficiency, and sustainable growth.

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