1.Raw material cutting: Select solid round steel bars based on the maximum outer diameter and length allowance of the finished product. Cut to length using a saw, leaving allowance for forging and machining.2.Forging: Round steel bars are fed into a heating furnace and heated to the forging temperature. Local rough forging/pre-forming is performed using a pressure forging press, forging the approximate shape of the blank (large and small end prototypes). Post-forging normalizing/annealing heat treatment: eliminates forging internal stress, improves metallographic structure, and prevents cracking during subsequent processing. Initial inspection of the blank appearance: checks for surface cracks, wrinkles, and forging defects.
3.Rough turning: The CNC lathe clamps the blank and rough turns the outer diameter: rough machining the outer diameter of the large end, the tapered transition section, and the outer diameter of the small end. A center drill is used for positioning, and a deep hole drill/boring tool is used for rough boring of the inner hole, leaving allowance for finishing. Most of the allowance is removed, and the overall dimensions of the blank are standardized.
4.Finishing: Precision machining of the outer contour: Accurate machining of the large end, taper transition area, and small end outer diameter to ensure concentricity.Precision boring of the inner hole: Controlling the inner diameter and inner wall surface finish to ensure coaxiality of the inner holes at both ends.End face flattening and chamfering; machining beveling (butt welding BW) or threading (NPT/BSP), and socket steps (SW socket welding) as required.Dimensional inspection: Verifying the outer diameter, wall thickness, length, and taper using calipers, micrometers, and a concentricity gauge.
5.Non-destructive testing (mandatory process for high-pressure pipe fittings)Select as needed based on pressure rating:MT Magnetic particle testing (carbon steel) / PT Penetrant testing (stainless steel): Detects surface micro-cracksUT Ultrasonic testing: Detects internal inclusions and voids.A non-destructive testing report is mandatory for high-pressure products.
6.Surface Treatment: Stainless Steel: Polishing, Pickling and Passivation. Removes machining burrs and metal filings, improving rust resistance and appearance.
7.Marking and Packaging: Stamped markings: Material, specifications, pressure rating, furnace batch number. Clean the inner bore and seal pipe openings to prevent impurities from entering. Sort and pack according to type, accompanied by material certificate, flaw detection report, and certificate of conformity.