forging

Strict requirements for raw materials

We attach importance to the influence of steel on the quality of gears.

To achieve optimal gear performance and precision, Chamol places great emphasis on selecting high-quality raw materials. Drawing on our extensive application experience, we communicate fully with customers before commencing work to identify the most suitable and economical steel grade based on specific application scenarios. We may recommend either carbon steel or alloy steel, or accommodate customer requests for specific steel grades.

With a warehouse containing approximately 500 tons of raw material, Chamol is able to commence gear production within a matter of hours. While our competitors are still selecting their material suppliers, we have already started the forging or heat treatment process with our own in-house material. However, it is important to note that the quality of steel can vary significantly between different mills. For this reason, we only partner with the world’s leading steel mills, including Arcelor Mittal, Nisshin Steel, OVAKO, Sumitomo, CITIC (Xingcheng Steel), and Baosteel, to ensure consistent and high-quality raw materials for our products.

Advanced forging knowledge leads to higher-quality gears.

In the gear production process, forging gear blanks is an essential step to ensure the performance and durability of the gears. Forging is done to give the gear blank excellent strength and density, which translates to better performance and longer service life. Furthermore, the forging process can improve the material’s microstructure and grain flow, further enhancing its mechanical properties.

As a custom gear manufacturer, we understand the importance of producing high-quality gears that meet our customers’ specific needs. At Chamol, we place great emphasis on the quality control and cost-effectiveness of gear blank forging.

Chamol is capable of forging gear blanks with complex shapes and strict tolerance requirements with high precision. This is achieved through our advanced forging equipment and experienced staff, who oversee every step to ensure accuracy and consistency.

In conclusion, forging gear blanks is a crucial part of our gear manufacturing process, and we place great importance on ensuring that our products meet the highest quality standards. Through continuous improvement of our forging knowledge, we strive to minimize material waste generated during the gear cutting process. You can rely on us to provide reliable, high-performance products that meet your specific needs.

Forging process

1. Material

Select appropriate raw materials and sizes according to production needs and customer requirements.

2. Steel testing

In order to ensure the quality of raw materials, the chemical composition of raw materials shall be rechecked before production.

3. Cutting

According to the size of bevel gear and customer requirements, cut ingot and billet into reasonable size and weight.

4. Heating

The cut raw materials are heated according to the product process to ensure that the heating temperature meets the material requirements.

5. Forging

Materials are put into the forging equipment by the manipulator. According to the size of raw materials and the requirements of forging ratio, corresponding technologies such as pier diameter and drawing length are carried out. The forging size is monitored in real time, and the forging temperature is controlled by infrared thermometer.

6. Forging test

Conduct preliminary inspection of forging blanks, mainly the inspection of appearance and size. In terms of appearance, the main inspection is whether there are cracks and other defects. In terms of size, we must ensure that the blank allowance is within the range required by the drawing and make a good record.

7. Heat preservation and normalizing

Through heat preservation and normalizing, grain refinement, uniform structure and elimination of internal stress can be achieved. Improvement defects: overheating defects such as Weisite, coarse grain size and banded structure. Prepare for heat treatment.

8. Rough finish

After forming the forgings, according to the product demand, it will be processed into a variety of different specifications of forgings, and keep the finishing allowance.

9. Heat treat

The forgings are heated to a predetermined temperature, held for a certain amount of time, and then cooled at a predetermined rate to improve the internal organization and properties of the forgings. Its purpose is to eliminate internal stress, prevent deformation during machining, adjust the hardness to make the forging conducive to cutting. After heat treatment of the forging, according to the requirements of the material of the forging, air cooling or water cooling, oil cooling, etc. Including: normalizing, tempering, quenching and other heat treatment.

10. Finish machining

The forging blanks after rough machining and heat treatment are processed by CNC machine tools, so that the dimensional accuracy and finish of the blanks fully meet the needs of gear production and customer requirements.

11. Visual inspection

Carry OUT ULTRASONIC flaw DETECTION (UT), MAGNETIC PARTICLE FLAW detection (MT), hardness, carburizing and other testing contents to ensure that the product appearance meets the needs of production gear and customer requirements.

12. Mechanical performance testing

In order to meet the requirements of customers and the technical standards of bevel gear production, it is necessary to test the mechanical properties of forgings, mainly the yield, tensile, impact and metallographic tests.