Precision Machining: Full-Process Manufacturing Services from Casting to Finished Products

Introduction

Machining is a basic process in the manufacturing industry. Through various processing equipment, metal materials are cut, formed, and processed to obtain the required shape, size, and surface quality. Henan Sankuang Machinery Technology Co., Ltd. provides full-process manufacturing services from wear-resistant casting to precision machining, especially specializing in precision machining of transmission components such as gear shafts.

Overview of Machining Technology

Machining is a process of obtaining part shape and accuracy by removing material, and is an indispensable and important link in modern manufacturing.

Main Processing Methods

1. Turning

1. Mainly used for processing rotary parts

2. Can process internal and external cylindrical surfaces, conical surfaces, threads, etc.

3. Accuracy can reach IT6-IT7 grades

2. Milling

1. Used for processing planes, grooves, curved surfaces, etc.

2. Divided into vertical milling and horizontal milling

3. Suitable for complex shape part processing

3. Grinding

1. Used for finishing to obtain high precision and low roughness surfaces

2. Including cylindrical grinding, internal grinding, surface grinding, etc.

3. Accuracy can reach IT5-IT6 grades

4. Gear Machining

1. Hobbing, gear shaping, gear shaving, gear grinding and other processes

2. Processing various types of gears and gear shafts

3. Gear profile accuracy can reach grades 6-7

5. Drilling and Boring

1. Used for hole processing

2. Drilling, reaming, countersinking, boring, etc.

3. Ensure hole dimensional accuracy and position accuracy

Gear Shafts: Typical Precision Machining Products

Gear shafts are typical complex parts in machining, integrating the functions of gears and shafts, with high requirements for machining accuracy.

Gear Shaft Processing Flow

1. Blank Preparation

1. Material selection: High-quality alloy steels such as 42CrMo, 20CrMnTi, SAE 8620H

2. Forging: Improve material structure and mechanical properties

3. Normalizing/annealing: Improve cutting performance

2. Rough Machining

1. Rough turning of outer diameter: leaving machining allowance

2. Rough milling of tooth profile: leaving finishing allowance

3. Drilling center holes: as benchmark for subsequent processing

3. Heat Treatment

1. Carburizing and quenching: Improve gear surface hardness

2. Or induction hardening: Local surface hardening

3. Tempering: Eliminate stress and adjust hardness

4. Finish Machining

1. Lapping center holes: Ensure machining benchmark accuracy

2. Fine grinding of outer diameter: Ensure shaft diameter accuracy

3. Gear grinding: Ensure tooth profile accuracy

4. Other finishing: Keyways, threads, etc.

5. Inspection and Acceptance

1. Dimensional inspection: Each shaft diameter, gear parameters

2. Geometric tolerance inspection: Coaxiality, circular runout, etc.

3. Hardness testing: Surface and core hardness

4. Flaw detection: Internal defect inspection

Processing Difficulties and Solutions

• Tooth profile accuracy control: Using CNC gear grinding machines with online detection and compensation

• Heat treatment deformation control: Optimizing heat treatment process, using press quenching technology

• Coaxiality guarantee: Completing multi-station processing in one setup

• Surface quality control: Using grinding and superfinishing processes

Combination of Wear-Resistant Casting and Machining

Henan Sankuang Machinery not only provides precision machining services but also has wear-resistant casting capabilities, enabling full-process production from castings to finished products.

Wear-Resistant Casting Technology

1. Sand Casting: Suitable for medium and large castings

2. Investment Casting: Suitable for castings with complex shapes and high precision requirements

3. Special Casting: Select appropriate casting processes according to product characteristics

Common Wear-Resistant Materials

• High Manganese Steel: ZGMn13, suitable for impact wear conditions

• High Chromium Cast Iron: Cr15, Cr20, Cr26, high hardness and wear resistance

• Alloy Cast Steel: 40Cr, 42CrMo, etc., with good comprehensive performance

• Bimetallic Composite: Wear-resistant surface, tough core

Characteristics of Cast Steel Machining

1. Large Machining Allowance: Low dimensional accuracy of castings requires large machining allowance

2. Uneven Surface Hardness: Casting surfaces may have hard skins, requiring special tools

3. Internal Defect Risks: May have casting defects such as pores and sand holes

4. High Processing Difficulty: Wear-resistant materials usually have high hardness and are difficult to process

Our Processing Capabilities

Equipment Configuration

• Large CNC Lathes: Maximum processing diameter 2000mm, length 5000mm

• CNC Milling Machines/Machining Centers: 3-axis, 4-axis, 5-axis machining centers

• CNC Gear Hobbing Machines: Maximum module M50, maximum diameter 3000mm

• CNC Gear Grinding Machines: Machining accuracy above grade 6

• Cylindrical Grinding Machines: Maximum grinding diameter 800mm, length 3000mm

• Heat Treatment Equipment: Pit-type carburizing furnaces, high-frequency quenching equipment, etc.

Processing Range

• Maximum Processing Diameter: 3000mm

• Maximum Processing Length: 5000mm

• Maximum Single Piece Weight: 20 tons

• Machining Accuracy: IT6-IT7 grades

• Surface Roughness: Ra0.8-Ra1.6μm (after grinding)

Service Fields

• Mining Machinery: Equipment parts such as crushers, ball mills, hoists

• Construction Machinery: Transmission components of excavators, cranes, etc.

• Metallurgical Equipment: Spare parts for rolling mills, continuous casters, etc.

• Wind Power Equipment: Gearboxes, slewing bearings and other components

• Petrochemical Industry: Pump, valve, compressor and other accessories

Why Choose Henan Sankuang Machinery?

1. Full-Process Manufacturing Capability

One-stop service from wear-resistant casting to precision machining, reducing intermediate links.

2. Rich Processing Experience

More than ten years of machining experience, especially specializing in precision machining of transmission components such as gear shafts.

3. Advanced Processing Equipment

With multiple large CNC processing equipment, we can meet the processing needs of various complex parts.

4. Strict Quality Control

Complete quality management system with full-process quality traceability from raw materials to finished products.

5. Flexible Customization Services

We can process various non-standard parts according to customer drawings or samples.

Contact Us

If you need precision machining, gear shaft processing, or wear-resistant casting services, please contact us!

Company Name: Henan Sankuang Machinery Technology Co., Ltd.Address: Luoyang City, Henan Province

We will provide you with high-quality products and services!