Densen Forge : Precision Craftsmanship And Customized Solutions for Mining Machinery Components

I. Forging technology: technological heritage and innovative breakthroughs

Densen Forge has been deeply engaged in the forging field for decades, using hot forging, warm forging, cold forging as the core technology, combined with free forging, open die forging, closed die forging,ring forging and other advanced technologies, to provide customers with high-precision, high-performance metal parts.

Hot forging process (>800℃)

Through high-temperature plastic deformation, it optimises the flow line of metal fibres and improves the impact resistance and fatigue strength of forgings, which is suitable for key components of mining machinery that are subject to heavy loads, such as forged gear shafts and forged spindles.

Precision closed die forging

No flying edge design makes the material utilisation rate as high as 95%, combined with CNC machine tools and fully automated production lines, we are able to mass produce Forged splined sleeve and Gear shaft forging with complex structure, with an accuracy of ±0.1mm. The company's products are available in a wide range of sizes and sizes.

Warm forging and cold forging technology (300~800℃/room temperature)

Reduces energy consumption while achieving precision forming of high-strength alloys, especially suitable for Precision forged components, such as wear-resistant liners and connectors, with a surface finish of Ra1.6.

Precise control of the entire process

Adopting forging simulation system to optimise process parameters; equipped with 10,000-ton hydraulic presses and high-speed forging hammers to support the production of super-large forgings with weights ranging from 0.1kg to 35 tonnes per piece.

Ⅱ.Customized mining machinery parts: performance and scenario adaptation

Densen focuses on providing highly durable and high load-bearing customized forging solutions for the mining industry, covering the entire process of mining, transport and crushing equipment needs.

Factory Profile:

Products: Gears, Gear Shafts, Turbines, Worms, Loose Gears, Helical Loose Gears

Equipment: Gear hobbing machines, gear shaping machines, gear grinding machines

Heat treatment: carburising and bonding, high-frequency quenching

Commonly used materials:

1. 18CrNiM6: commonly used material in wind power industry, good toughness, good wear resistance

2.42CrMO

3.45# steel

Industry: wind power, shipbuilding, train, machine tool gears

Production value:7-8 million

Core Product Matrix:

Forged splined shaft: 42CrMo alloy steel, torsional strength up to 1200MPa, suitable for heavy-duty mining truck transmission system.

Forged gear shaft: modular design supports customization of tooth shape and keyway, and the life span is more than 3 times higher than that of cast parts.

Precision forged components: covering hydraulic pillars, bearing housings, etc. They have passed ISO 9001/14001/45001 certification and meet the needs of harsh underground working conditions.

Application Scenario:

Crusher core components: Jaw plate, hammer head, etc. are forged with wear-resistant steel with hardness HRC55-60, reducing the frequency of downtime replacement.

Conveyor system components: sprockets, drum shafts, etc. are made of full-fibre flow-forming technology, which improves fatigue resistance by 40%.

Φ 13000 mm heavy duty ball mill ring gear

Advantage of Densen factory: Intellectual strength and global delivery

Full Industry Chain Coverage

From alloy melting, precision forging to heat treatment and machining, Densen achieves one-stop delivery of ‘forgings - finished products’, shortening customers' supply chain cycle.

Intelligent Quality Inspection System

Equipped with 3D scanner, ultrasonic flaw detector and other equipments to ensure the Industrial forging manufacturer standard, with the pass rate of key dimensions ≥99.8%.

Green Manufacturing Capability

Adopting waste heat recovery system and low-emission process, the energy consumption per unit of product is 15% lower than the industry average, and complies with EU CE and North America API certification.

Global Service Network

Setting up several large production bases, supporting small batch trial production to 10,000-ton orders, and providing fast technical solution response.

Open up efficient co-operation

Whether you need to optimise standard parts or customize for complex working conditions, Densen will take Forge Your Excellence as its mission and provide full-cycle services from design support to batch delivery.