Forging, casting, cutting, and rolling are the most common flange manufacturing processes.
Casting and forging flanges offer the advantage of having accurate shape, size, and inexpensive costs, as well as requiring a simple technique. Forging flanges, on the other hand, have production flaws such as blowholes and cracks, as well as a clumsy internal structure. Forging flanges offer the obvious advantages of being able to be forged in a variety of shapes and having inexpensive prices.
Forging flanges have a lower carbon content and are less resistant to rusting than casting flanges. Casting flanges have a clean streamline, consistent internal organisation, and poor mechanical performance. There are no flaws in the casting flanges, such as blowholes or cracks. Casting flanges can bear more shear and pulling forces than forging flanges. However, if the forging process is done incorrectly, huge, irregular grains and solidification cracks will emerge, resulting in a higher cost than casting flanges.
From the varied production processes, we can distinguish between casting flanges and forging flanges. The centrifugal flange, for instance, is a type of casting flange. Centrifugal flanges are made using a precision casting technology, which reduces the organisation of the flanges compared to sand casting and increases the quality of the flanges by reducing loose tissue, pore, and sand hole occurrences.
The cutting method involves cutting a round plate with the inner diameter, outside diameter, and thickness that may be treated later from the central plate, and then processing the bolt hole and waterline. The width of the central plate limits the maximum diameter of such flanges.
The cutting technique involves cutting stripes from the central plate and then rolling them into a spherical shape to make flanges. This method is mostly used to create huge flanges. Weld and flatten the circular shape after the rolling process, then process the serrated spiral finish and bolt hole.