Y&J Industries has reached a remarkable milestone with successful development of volute castings for heavy-duty expansion compressors. It represents our great achievement in our development of a new product category this year.
Embracing Challenges and Overcoming Obstacles
1. High Casting Difficulty: Castings are quite large, with weight of 12 ton, 6 ton and 3ton. Their complex structure in terms of casting is prone to deformation and very high level of NDT acceptance is required –level 1 for critical area and level 2 for non-critical area.
2. Complex and High Precision Machining: Multiple machining equipment—including vertical lathes, gantry mills, and horizontal boring machine are involved in numerous cross-operations. To prevent deformation, machining references had to be adjusted repeatedly. The conical inner cavity of the castings required extremely high precision and smoothness, tolerating no mistakes, even minor deviations.
3. Challenging Assembly and Pressure Testing: It is also required the pressure test must be carried out in the same way as that for the assembled finished product. We independently designed tooling to simulate the final installation state and carried out related tests.
4. Exceptionally Tight Schedule: The delivery time we were given was only 130 days, which is significantly shorter than the usual 200 days. This poses a huge challenge for our team because all works including technical analysis, quality planning, casting, machining, assembly, pressure testing, and inspections has to be finished in a significantly condensed timeframe.
Meticulous Management Ensuring Progress
1.Project Planning and Follow-Up: Each step—from quality requirement and technical specifications to mold manufacturing and casting simulation—was carefully planned and communicated.
2.Progress Monitoring: The team strictly controlled key milestones, conducting quality inspections at critical junctures like mold completion, casting, and rough machining to ensure standards were met.
Significant Impact and Future Outlook
The completion of this project is regarded as a big leap forward for Y&J in manufacturing intricate, large-scale industrial compressor components. Collaborating with globally leading customers has elevated Y&J's technical capability and industry influence.
