Shanxi Jianing Forging has collected real-world engineering cases of long shafts, short shafts, drive shafts, and marine nuclear power shaft forgings, fully showcasing the forging process of shaft forgings, finished product precision, and practical application scenarios for heavy equipment.
In the Shunyi area of Beijing, a metallurgical parts factory has long been engaged in the production and supply of various metal parts. Recently, the factory encountered a technical bottleneck in the processing of shaft forgings. After extensive investigation and comparison, they ultimately chose Jianing's forging solution. Below is a detailed analysis of this case.
This metallurgical parts factory mainly undertakes orders for shaft-type forgings in large machinery equipment, with strict requirements for product mechanical properties, dimensional accuracy, and delivery times. Due to the low efficiency of the original processing methods and the difficulty in maintaining a stable finished product pass rate, the factory faced insufficient production capacity and increasing customer complaints.
1. The internal structure of shaft forgings is uneven, causing some products to develop cracks during subsequent heat treatment and increasing the defect rate. 2. The current forging equipment has limited capacity and cannot meet the forming needs of large-sized shaft parts, requiring outsourced processing, resulting in long cycles and high costs. 3. Low material utilization and large blank allowance, increasing the difficulty of subsequent machining. 4. Lack of a mature process parameter system, reliance on worker experience, and large quality fluctuations.
To address these pain points, Jianing Forging provides customized overall shaft forging solutions:
Process optimization: Using multi-directional forging combined with temperature-controlled forging technology, the metal flow lines are distributed more evenly along the axis, eliminating internal looseness and segregation, thereby increasing the density of forgings.
Equipment matching: Using Jianing Forging's large-tonnage forging press, large-section shaft parts are formed in one go, reducing intermediate heating steps and shortening processing cycles.
Material Savings: Through finite element simulation analysis, material distribution and pre-forging steps are optimized, keeping blank allowance within a reasonable range, and improving material utilization by about 12%.
Process curing: Establishing standardized forging operation instructions for parts factories, combined with online temperature measurement and deformation monitoring systems, to achieve process control and reduce human influence.
After batch trial production and third-party testing, all mechanical properties of the factory's shaft forgings met the drawing requirements, with a pass rate stable above 98%, delivery times shortened by 30%, and overall costs reduced by about 15%. Currently, both parties have established a long-term cooperative relationship, and the factory's production efficiency and market competitiveness have both improved.
