Axle Shaft Forging Solution

What We Gives to Industry

Forging Consultant Group provides complete automobile axle shaft forging solutions, including heating, upsetting, and rotary forging. We specialize in spline shafts and axle shafts for heavy commercial trucks and lightweight vehicles, delivering high precision, strength, and reliability. Our turnkey solutions cover the entire forging process, ensuring efficient production, minimal scrap, and faster ROI for clients globally.

Axle Shaft Forging Process – Step by Step

Forging Consultant Group – Your Partner for Precision Forgings

1. Billet Preparation

Material: Alloy steel (e.g., 42CrMo4/4140)
Process: Cut to length + 5–10% extra for flash/machining, deburr, chamfer ends, verify chemistry/UT.
Key: Straight, clean surface avoids laps/non-fill.
Traceability: Mark heat/lot.
Image Prompt: “Cut alloy-steel billets with ID tags and chamfered ends on a workshop table, high-detail, realistic lighting.”

2. Heating

Temp: 1150–1200°C (induction/furnace), maintain core above 950–1000°C.
Protection: Anti-scale or protective atmosphere.
Image Prompt: “Billet glowing orange in furnace, IR pyrometer reading visible, light anti-scale coat applied, industrial background.”

3. Upsetting

Goal: Thicken flange end 30–50% without buckling.
Lubrication: Graphite or high-temp lubricant.
Temp: Keep above 1050°C.
Image Prompt: “Hot billet being upset by press, showing before-and-after flange height, industrial press view.”

4. Preform

Shape: Disk-like flange + tapered neck, balance material for blocker fill, maintain fillet stock.
Image Prompt: “Preform with distinct flange disk and neck profile on layout board with gauges, top view.”

5. Blocker Forging

Action: Achieve near-net OD, pilot, and fillet volume with continuous flash.
Die Temp: 200–300°C.
Image Prompt: “Blocker die cross-section with workpiece showing uniform flash ring, industrial die setup.”

6. Finisher Forging

Objective: Final bolt face, hub thickness, radii, light coining if needed.
Temp: Above 1000–1050°C.
Image Prompt: “Finisher die closed on workpiece; ejected part with crisp features, industrial lighting.”

7. Trimming & Deburring

Operations: Hot-trim flash, shotblast, deburr, pierce as required.
Key: Maintain flatness, rim integrity.
Image Prompt: “Trimming press removing flash ring; trimmed part on table, operator in background.”

8. Heat Treatment

Type: Quench & temper (4140 → 28–36 HRC) or normalize.
Temp: Temper at 540–650°C; control distortion.
Image Prompt: “Basket of billets entering furnace; microstructure inset showing tempered martensite.”

9. Machining

Datum: Pilot & bolt face.
Operations: Turn pilot OD, face flange, drill/ream bolt circle, chamfer holes.
Inspection: CMM for runout, surface finish Ra 1.6–3.2 µm.
Image Prompt: “CNC turning billet pilot and flange, CMM probe measuring runout, workshop background.”

10. Inspection & Protection

Checks: CMM, MT, hardness mapping, visual for laps/underfill.
Protection: Phosphate + oil or VCI wrap. Mark part number & heat code.
Image Prompt: “Hardness tester on face, MT yoke inspection on fillet, coated parts in VCI wrap.”

Image Set Summary:

Die design cross-section with grain flow arrows
Heated billet with pyrometer
Upset end comparison
Preform shape on layout board
Blocker fill with flash
Finisher strike result
Trimming operation
Heat-treat furnace and micrograph
CNC machining with CMM probe
MT inspection and coated parts

Favored Forging Consultant Group Highlights:

Expertise: Axle/drivetrain forgings
Services: Die design, FE simulation, PPAP, cost/yield optimization
Benefits: 8–15% flash reduction, 20–30% die-life gains, improved first-pass yield
Engagement: Remote review, on-site line study, three-run tryout