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.
A certain petrochemical machinery factory purchased a batch of high-pressure shaft forgings for key transmission components due to equipment upgrades. The factory has strict requirements for the internal density, dimensional stability, and mechanical properties of forgings. After multiple rounds of technical comparison, they ultimately chose to cooperate with Jianing Forging, which custom-developed this batch of shaft forgings.
This customer has faced multiple challenges in past production:
1. Traditional open-die forging processes cause loose cores in shaft forgings, with ultrasonic flaw detection pass rates below 80%;
2. The product's mechanical properties fluctuate greatly, with tensile strength and yield strength exceeding 15% within the same batch;
3. Excessive allowance for external cylindrical machining, material utilization rate of only about 60%, resulting in cost waste;
4. Long delivery cycles, making it difficult to match the commissioning dates for new production lines.
To address these pain points, Jianing Forging offers customized solutions:
1. Utilizes multi-directional forging technology, combined with continuous upsetting and large deformation control, effectively eliminating casting defects, increasing core density, and maintaining a UT flaw detection pass rate above 98%;
2. Introduced a relatively accurate temperature control system (±5°C), combined with segmented heat treatment after forging, to control tensile strength deviation within ±5% of products in the same batch, significantly improving hardness uniformity;
3. Optimized forging die and allowance design, compressing the outer cylindrical allowance of shaft forgings from 10mm per side to 6mm, increasing material utilization to 76%, and saving about 8% of raw material costs per piece;
4. Through lean scheduling and quick mold change technology, the standard delivery cycle has been shortened from 45 days to 28 days, meeting customers' urgent production start-up needs.
