MCC Heavy Industry has built three multi-directional die forging production lines, creating a “smart factory” for producing complex forgings for high-end equipment. Through “intelligent linkage + precision control,” they have overcome the challenges of producing complex forgings. For example, the 40-meganewton multi-directional die forging line features a fully automated production process. A robotic arm precisely feeds metal billets heated to 1100°C into the die. Three sets of punches then apply pressure simultaneously from different directions, forcing the metal to flow along the die cavity, forming the complex forgings in a single step. This eliminates the multiple forging presses and subsequent processing required by traditional forging. The line’s intelligent monitoring system monitors forging parameters such as pressure, temperature, and time in real time, automatically adjusting any deviations from set values ​​to ensure dimensional accuracy within 0.2 mm. The system also records production data for each forging, enabling full traceability and facilitating subsequent quality inspections. Compared to conventional forgings, the forgings produced by this production line are flash-free and resemble finished parts, reducing subsequent processing time by 60%. They also feature finer metal grains, triple fatigue life, and over 20% improved mechanical properties. Currently, the production line supplies key forgings for wind turbine spindles and nuclear power pressure vessels for wind power, nuclear power, and aviation, driving the intelligent and domestically produced manufacturing of high-end forgings in my country.

Northern Heavy Industries’ 5.5-meter cropping shear and cut-to-length shear are the “precision benchmark” in the steel rolling process. Leveraging a “rolling-cut design + intelligent control,” they significantly improve steel yields. During the steel rolling process, these shears must precisely cut steel billets to the specified length. Traditional flat-blade shears are prone to burrs and bends. This equipment, however, utilizes the cutting-edge rolling shearing principle. The upper and lower blades rotate and roll to shear the billets, achieving a shearing accuracy of 0.1 mm. It can shear large billets up to 80 mm thick and 5.5 meters wide. To enhance equipment stability, the hydraulic system utilizes an electro-hydraulic proportional valve + closed-loop control to adjust the shearing force in real time. It automatically adjusts pressure when billet hardness fluctuates to prevent blade breakage. The modular design divides the equipment into modules: the shearing unit, transmission unit, and control system. Failure of any module can be individually disassembled and replaced, reducing maintenance time from 72 hours to 12 hours and increasing equipment utilization by over 30%. Furthermore, the energy management system improves the equipment’s overall energy efficiency by 15% by optimizing operating parameters. In use at a large steel company, this equipment has increased the steel shearing qualification rate from 95% to 99.8%, reducing steel waste by over 1,000 tons annually. This provides strong support for cost reduction and efficiency improvement for the steel company and fills a gap in the domestic production of high-end shearing equipment in my country’s steel and metallurgical industry.