Case Study: Larsen & Toubro achieves 5% material savings in hydro shaft manufacturing with Hexagon Simufact Forming

Larsen & Toubro - Customer Case Study

Larsen & Toubro (L&T) Special Steels and Heavy Forgings faced a challenge optimizing material usage during the manufacturing of large-diameter hydro shafts. A significant source of material loss and dimensional issues was the unpredictable flow of the "bottom discard" portion of the ingot during multiple hot forging operations, which led to wasteful bulging. To address this, the company employed Hexagon's Simufact Forming software to accurately simulate and study the material flow patterns.

Using Hexagon's simulation solution, L&T was able to modify the upsetting profile and forging process to precisely control the metal flow and prevent the bottom discard from mixing with the sound material. This resulted in over a 5% saving in material, contributing to significant cost competitiveness and increased order inflow. The solution from Hexagon also improved dimensional control and reduced the need for costly and time-consuming shop trials.

Larsen & Toubro

Amit Gupta

Chief Executive