Forging is a technique in which a metal or an alloy in a hot or cold state is plastically deformed by applying pressure (hammer forging, die forging, impact hammer) or one-time application of pressure (pressure forging or rolling forging). Hammer forging and die forging are only suitable for hot metals, while pressure forging is also used for cold metals. Forging can be carried out by human or mechanical means.
The forging process involves cutting the material to the desired size, heating, forging, heat treating, cleaning, and inspection. In small manual forging, all of these operations are carried out by a few blacksmiths in the narrow place. They are exposed to the same harmful environmental and occupational hazards; in large forging workshops, the hazards vary from job to job.
Working conditions Although working conditions vary from forging to form, they have some common characteristics: moderate-intensity physical labor, dry and hot microclimate environments, noise and vibration, and air pollution by smoke.
The energy consumption varies between 3 and 6 kcal/min (12.56 to 25.12 kJ/min) depending on the type of forging and the level of mechanization. It has been found that in a working day of mechanized forging, such as 70% of the time for forging, the average energy consumption is 4.5 kcal (18.84 kJ / min); 10% for auxiliary work, the average consumption is 2 Kcal/min (8.37 kJ/min); 20% for organizing work and rest. The average consumption is 1 kcal/min (4.19 kJ/min). Its total consumption is 1750 kcal / day (7324 kJ / day), which makes the forging work at the upper limit of medium and heavy physical labor, and the required neuropsychiatric power is also between the limits of medium physical and heavy physical labor.
A notable feature of the microclimate environment is the high temperature. The high temperature is the wall of the electric furnace (100~180°C) and the feeding gate (220~260°C), the hot metal (800~900°C) and the tools and the hot metal from the place. The radiant heat of the ground (above 35 °C) is caused by a poorly ventilated forging workshop, which can rise by 40 to 43 °C during the hot season. In the large forging workshop, there is high-intensity radiant heat (0.8~5 kcal/cm2·min or 3.35~20.93 kJ/2·coke or 3.35~12.56 kJ/cm2·min), but exposed Longer time (85% of working days). The relative humidity is usually 15~50%, the airflow speed is 0.4~1.0m/s in summer, and in winter, the airflow speed near the door can be as high as 6m/sec.
Workers are exposed to both high temperature air and heat radiation, causing heat to accumulate in the body. Heat and metabolic heat can cause heat loss and pathological changes. The amount of sweat per hour of labor will vary from 1.5 to 5 liters, or even higher, depending on the small gas environment, physical exertion, and degree of thermal fitness. In the smaller forging workshops or farther away from the heat source, the Beha Ershi heat stress index is usually 55 to 95; but in large forging workshops, the working point near the furnace or the drop hammer machine may be as high as 150 to 190. Easy to cause salt deficiency and enthusiasm. In the cold season, exposure to changes in the microclimate may promote adaptation to a certain extent, but rapid and too frequent changes may constitute a health hazard.
Airborne workplaces may contain soot, carbon monoxide, carbon dioxide, sulfur dioxide, or acrolein, depending on the type of fuel and the impurities contained in the furnace, as well as combustion efficiency, airflow, and ventilation.
Noise and Vibration Large forging hammers inevitably produce low frequency noise and vibration, but may also have a certain high frequency component with a sound pressure level between 95 and 115 decibels. Exposure of workers to forging vibrations can cause temperament and functional imbalances that can reduce work capacity and impact safety.
Hazards Accidents may be caused by imperfect molds and environmental conditions, or due to unsafe operation, poor organization, or lack of equipment and personal protective equipment.
Sudden accidental fall of the drop hammer ram during machining or when changing the mold can cause serious injury. Many accidents can be prevented if the ram is supported by effective supports and retaining blocks. The enclosed pedal with shroud also prevents accidental movement of the forging bed.
Metal tools used to transfer hot forgings may suddenly pry out from between the molds and hit the operator. If you do not wear a protective eye mask, the flying hot chips may damage your eyes. Heat-resistant arm guards, shoe covers, and aprons protect the arms and legs from all kinds of burns, while safety shoes protect the toes from crushing.
Although the harmful factors in the working environment may constitute occupational and induced pathological conditions, the normal effects of these harmful factors are reflected in the emergence of certain diseases, or by reducing the total resistance of the human body. The incidence rate. From the perspective of the incidence of blacksmiths, the most important disease categories are: chronic rheumatism, burns, indigestion (entenes), respiratory disorders, and skin inflammation. Occupational disorders are: various disturbances caused by hearing loss and local vibration caused by strong noise and vibration.
Safety and hygiene measures Proper workshop layout can greatly improve working conditions. Heating furnaces and forging equipment should be placed in the correct position, avoiding intensive one place, the workpiece process should be reasonable, and the finished forgings should be moved out of the workshop. If possible, the processing should be Mechanized and well managed. The furnace should have good airflow; furnace smoke, soot and hot air should be discharged outside the workshop. Radiant heat sources and air should be insulated by water curtains, reflective or insulated barriers. The forging workshop should have effective full-plant ventilation (designed natural ventilation is generally acceptable), the furnace should have a local exhaust system, the high-temperature workplace should be equipped with a cold air shower device, and a wind curtain should be installed around the door. An insulated lounge should be provided with air showers and sprinklers. Studies have shown that under working conditions, people can obtain thermal adaptability in a forging workshop with a temperature of 19 to 24 ° C, a relative humidity of 30 to 50%, and a gas flow rate of 0.5 m / s. To avoid excessive stress, the effective temperature should not exceed 27 °C.
Hazardous noise sources should be enclosed or equipped with acoustic panels, and the workshop should be kept away from residential areas. In order to suppress vibration, the equipment should be installed on a deep and thick foundation below the foundation of the building and separated from all structural components.
All workers should undergo a medical examination before being employed, and then regular inspections should be provided to them with personal protective equipment (especially hearing protection products). The pace of work should be reasonable. Drinks should be provided at work to supplement the water, salt and vitamins lost by sweating. The workshop should have adequate sanitation and all workers should receive good safety training.
The forging process involves cutting the material to the desired size, heating, forging, heat treating, cleaning, and inspection. In small manual forging, all of these operations are carried out by a few blacksmiths in the narrow place. They are exposed to the same harmful environmental and occupational hazards; in large forging workshops, the hazards vary from job to job.
Working conditions Although working conditions vary from forging to form, they have some common characteristics: moderate-intensity physical labor, dry and hot microclimate environments, noise and vibration, and air pollution by smoke.
The energy consumption varies between 3 and 6 kcal/min (12.56 to 25.12 kJ/min) depending on the type of forging and the level of mechanization. It has been found that in a working day of mechanized forging, such as 70% of the time for forging, the average energy consumption is 4.5 kcal (18.84 kJ / min); 10% for auxiliary work, the average consumption is 2 Kcal/min (8.37 kJ/min); 20% for organizing work and rest. The average consumption is 1 kcal/min (4.19 kJ/min). Its total consumption is 1750 kcal / day (7324 kJ / day), which makes the forging work at the upper limit of medium and heavy physical labor, and the required neuropsychiatric power is also between the limits of medium physical and heavy physical labor.
A notable feature of the microclimate environment is the high temperature. The high temperature is the wall of the electric furnace (100~180°C) and the feeding gate (220~260°C), the hot metal (800~900°C) and the tools and the hot metal from the place. The radiant heat of the ground (above 35 °C) is caused by a poorly ventilated forging workshop, which can rise by 40 to 43 °C during the hot season. In the large forging workshop, there is high-intensity radiant heat (0.8~5 kcal/cm2·min or 3.35~20.93 kJ/2·coke or 3.35~12.56 kJ/cm2·min), but exposed Longer time (85% of working days). The relative humidity is usually 15~50%, the airflow speed is 0.4~1.0m/s in summer, and in winter, the airflow speed near the door can be as high as 6m/sec.
Workers are exposed to both high temperature air and heat radiation, causing heat to accumulate in the body. Heat and metabolic heat can cause heat loss and pathological changes. The amount of sweat per hour of labor will vary from 1.5 to 5 liters, or even higher, depending on the small gas environment, physical exertion, and degree of thermal fitness. In the smaller forging workshops or farther away from the heat source, the Beha Ershi heat stress index is usually 55 to 95; but in large forging workshops, the working point near the furnace or the drop hammer machine may be as high as 150 to 190. Easy to cause salt deficiency and enthusiasm. In the cold season, exposure to changes in the microclimate may promote adaptation to a certain extent, but rapid and too frequent changes may constitute a health hazard.
Airborne workplaces may contain soot, carbon monoxide, carbon dioxide, sulfur dioxide, or acrolein, depending on the type of fuel and the impurities contained in the furnace, as well as combustion efficiency, airflow, and ventilation.
Noise and Vibration Large forging hammers inevitably produce low frequency noise and vibration, but may also have a certain high frequency component with a sound pressure level between 95 and 115 decibels. Exposure of workers to forging vibrations can cause temperament and functional imbalances that can reduce work capacity and impact safety.
Hazards Accidents may be caused by imperfect molds and environmental conditions, or due to unsafe operation, poor organization, or lack of equipment and personal protective equipment.
Sudden accidental fall of the drop hammer ram during machining or when changing the mold can cause serious injury. Many accidents can be prevented if the ram is supported by effective supports and retaining blocks. The enclosed pedal with shroud also prevents accidental movement of the forging bed.
Metal tools used to transfer hot forgings may suddenly pry out from between the molds and hit the operator. If you do not wear a protective eye mask, the flying hot chips may damage your eyes. Heat-resistant arm guards, shoe covers, and aprons protect the arms and legs from all kinds of burns, while safety shoes protect the toes from crushing.
Although the harmful factors in the working environment may constitute occupational and induced pathological conditions, the normal effects of these harmful factors are reflected in the emergence of certain diseases, or by reducing the total resistance of the human body. The incidence rate. From the perspective of the incidence of blacksmiths, the most important disease categories are: chronic rheumatism, burns, indigestion (entenes), respiratory disorders, and skin inflammation. Occupational disorders are: various disturbances caused by hearing loss and local vibration caused by strong noise and vibration.
Safety and hygiene measures Proper workshop layout can greatly improve working conditions. Heating furnaces and forging equipment should be placed in the correct position, avoiding intensive one place, the workpiece process should be reasonable, and the finished forgings should be moved out of the workshop. If possible, the processing should be Mechanized and well managed. The furnace should have good airflow; furnace smoke, soot and hot air should be discharged outside the workshop. Radiant heat sources and air should be insulated by water curtains, reflective or insulated barriers. The forging workshop should have effective full-plant ventilation (designed natural ventilation is generally acceptable), the furnace should have a local exhaust system, the high-temperature workplace should be equipped with a cold air shower device, and a wind curtain should be installed around the door. An insulated lounge should be provided with air showers and sprinklers. Studies have shown that under working conditions, people can obtain thermal adaptability in a forging workshop with a temperature of 19 to 24 ° C, a relative humidity of 30 to 50%, and a gas flow rate of 0.5 m / s. To avoid excessive stress, the effective temperature should not exceed 27 °C.
Hazardous noise sources should be enclosed or equipped with acoustic panels, and the workshop should be kept away from residential areas. In order to suppress vibration, the equipment should be installed on a deep and thick foundation below the foundation of the building and separated from all structural components.
All workers should undergo a medical examination before being employed, and then regular inspections should be provided to them with personal protective equipment (especially hearing protection products). The pace of work should be reasonable. Drinks should be provided at work to supplement the water, salt and vitamins lost by sweating. The workshop should have adequate sanitation and all workers should receive good safety training.
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