Forging large module gear shaft

Forging: Selection conditions for forging blanks

1. The material of the structural parts must have good forgeability
   Good forgeability is the basic condition for producing blanks by forging processing methods. For example, metal materials with poor forgeability such as cast iron, cast aluminum alloy, and sliding bearing alloy can only be produced by casting. Various structural steels, deformed aluminum alloys, and pressure-processed copper alloys can all be produced by forging. It can be seen that the selection of blank production methods is directly related to material selection.
2. The shape of the forged blank cannot be too complicated, especially there must be no inner cavity structure.
   For parts with simple appearance and single-piece production, free forging can be used to produce part blanks. For parts with more complex appearance and larger production batches, die forging or die forging can be used to manufacture part blanks. In addition, the shape and structure of the forging should also be considered according to the requirements for the processability of the forging structure in Section 4 of this chapter.
3. Structural forging blanks must be pre-heat treated
   During the forging process, due to the different final forging temperatures, deformation degrees and cooling rates of various parts of the forging, there will be defects such as uneven structure, residual internal stress and cold deformation strengthening inside the forging. This will not only reduce the quality of the forging, but also bring difficulties to mechanical processing and final heat treatment. For this reason, forgings are usually subjected to appropriate heat treatment. Through heat treatment after forging, the structure can be uniform, the grains can be refined, and the residual internal stress can be eliminated. This will prepare the organization for the final heat treatment (such as quenching). At the same time, because the hardness of the forging is adjusted, the cutting performance can also be improved.

Rough machining: Gear shafts with a modulus of more than 25 must be roughly toothed

Rough machining is the process of cutting off more machining allowances from the blank during mechanical processing. The accuracy that can be achieved is low, the machining surface is rough, and the productivity is high. It is often a preparatory process for semi-finishing and finishing. Our company stipulates that when the modulus is greater than 25, rough toothing must be performed, so that the tooth surface can obtain the best mechanical properties after quenching and tempering. This is our company’s special processing technology. Although the processing cost will be higher than ordinary, it can improve the mechanical properties of the teeth and thus increase their service life.

Heat treatment

Heat treatment is a very important process in the entire production process. Heat treatment is a very important process in the entire production process. Heat treatment usually doesn’t change the shape and overall chemical composition of the workpiece. Heat treatment imparts or enhances the performance of the workpiece by altering its internal microstructure or by modifying the surface chemical composition. The characteristic of heat treatment is that it improves the intrinsic quality of the workpiece in ways that are not visible to the naked eye. Our company believes that more than 80% of the life of mechanical parts depends on hot processing (steelmaking, casting, forging, welding, heat treatment). Our company is Luoyang’s large mold heat treatment engineering technology center and Nanjing industry-university-research, so we do some scientific research projects with universities and apply some cutting-edge technologies to our production.

1. Use a pit-type electric furnace; heating by radiation, the parts are heated very evenly, reducing the deformation of the workpiece. The biggest problem in mechanical manufacturing is the deformation of the workpiece. Heating by a pit furnace can minimize the deformation of the workpiece;
2. Complete quenching media: oil, synthetic quenching agent, water and brine. According to different materials and process requirements, different coolants are used for quenching, and the parts are cooled at the fastest cooling speed allowed and then tempered to obtain the best mechanical properties;
3. Huge cooling capacity, synthetic quenching agent and water are 450 tons, respectively. At the same time, a cooling circulation system is added to heat treat large parts;
4. Special furnace: Each heat treatment furnace is only equipped with one type of part so that the best process can be customized according to the size of the part. Our leader said that our heat treatment is for taxis, and many factories heat treat buses.

Packing & Delivery

In order to avoid the finish products rusted and damaged during the transportation ,we will design the right packing according to the shape,size and usage of the products.And the packaging materials are sustainable and recyclable, with little impact on the environment.