Case studies for close-die forging parts from both construction machinery parts and EV car components

Close-die forging is widely used in industries like construction machinery and automotive manufacturing due to its ability to produce strong, high-quality parts with precise shapes and minimal waste. Here are some case studies from both construction machinery parts and EV car components:

1. Construction Machinery Parts:

Case Study: Forging for Excavator Shafts

• Part: Excavator transmission shafts

• Forging Process: Close-die forging

• Description: Shafts used in heavy construction machinery, such as excavators, require high strength and wear resistance due to heavy loading conditions. Close-die forging is used to produce complex shaft geometries that enhance fatigue resistance. The forging process helps in producing parts with optimal material distribution, especially in high-stress areas.

• Outcomes:

• Improved strength and fatigue life of shafts.

• Reduced weight due to material optimization.

• Reduction in material wastage and overall costs.

Key Takeaways:

• Precision in dimensions and weight reduction are essential for the shaft's performance.

• Material  selection and heat treatment after forging are crucial for achieving desired properties (high tensile strength, toughness, etc.).

2. EV Car Components:

Case Study: Close-Die Forging of EV Drive Shafts

• Part: EV motor shafts and differential gears

• Forging Process: Close-die forging

• Description: As electric vehicles (EVs) become more common, manufacturers are turning to forging to produce critical drivetrain components such as shafts and gears. Aston Martin, for example, uses close-die forging for producing the shafts that connect the electric motor to the wheels, ensuring durability and optimal power transmission efficiency.

• Outcomes:

• Improved part performance with reduced weight.

• Increased component life and reliability under high torque conditions.

• Cost savings compared to other manufacturing methods (casting or machining).

Key Takeaways:

• Close-die forging allows for material grain alignment, which is important for fatigue resistance in drivetrain components.

• Tight dimensional control helps in reducing post-forging machining costs and ensuring better fit and finish.

• Lower energy consumption in comparison to casting methods, benefiting the overall sustainability of EV production.

3. General Case Study: Close-Die Forging for Heavy-duty Components

• Part: Forged shafts for heavy machinery and EV applications

• Forging Process: Close-die forging

• Description: Walkson has worked on producing forged components for various industries, including heavy-duty equipment and automotive, leveraging close-die forging to produce shafts, gears, and other drivetrain components.

• Outcomes:

• Components have high resistance to wear and high fatigue strength.

• Reduced porosity and inclusions in forged parts compared to cast parts.

• Enhanced precision and material usage efficiency.

Key Takeaways:

• Close-die forging is particularly beneficial for creating parts that need to withstand extreme operating conditions (high stress, high torque).

• Applications in both construction machinery and EVs benefit from the mechanical properties achieved through forging, which are vital for safety and performance.

Benefits of Close-Die Forging for Both Applications:

1. Strength and Durability: Parts undergo deformation in the die, which refines the grain structure of the material, improving its mechanical properties (strength, fatigue resistance).

2. Dimensional Accuracy: Close-die forging provides excellent control over part dimensions, reducing the need for post-processing.

3. Material Efficiency: Wastage is minimized compared to casting, as the process uses a near-net shape approach.

4. Cost-effectiveness: Although tooling costs for forging can be high, mass production of high-performance parts with minimal post-processing leads to overall cost savings.

For both construction machinery and EV components, close-die forging provides an ideal balance of performance and cost-effectiveness, especially for critical components where strength, precision, and material efficiency are paramount.