In the field of heavy machinery manufacturing, the quality of wheel forgings directly affects the forklift's load capacity, service life, and operational safety. A forklift heavy factory in Yangquan, Shanxi, once faced a series of technical challenges in wheel forging procurement. By introducing Jianing's professional forging solutions, they successfully optimized their production process and improved product quality.

1. Case Summary

This cooperation target is a heavy industry enterprise specializing in forklift manufacturing in the Yangquan area of Shanxi. The company has long produced various tonnage forklifts, with high requirements for the strength, wear resistance, and dimensional accuracy of wheel forgings. Due to shortcomings in internal microstructure density and fatigue life of forgings from previous suppliers, finished wheels develop cracks and deformation in the later stages of use, seriously affecting overall machine reliability and customer reputation.

2. Customer pain points

The core pain points customers encounter in actual production include:

• Frequent internal defects: Forgings have looseness, microcracks, and other internal defects, directly affecting the wheel's fatigue resistance under heavy load conditions.
• Poor dimensional consistency: Different batches of forgings fluctuate significantly in key dimensions (such as flange thickness and shaft hole diameter), resulting in uneven machining allowances and a high defect rate.
• Heat treatment deformation is difficult to control: Under traditional processes, forgings show obvious deformation after quenching and tempering, requiring additional correction steps and extending delivery cycles.
• Overall costs are relatively high: Due to unstable quality, customers must invest significant manpower in full inspections and repairs, and after-sales compensation risks persist.

3. Product Advantages (Jianing Forging Solutions)

To address these pain points, Jianing Forging offers systematic solutions from three dimensions: materials, processes, and inspection:

• Optimized material formulation and forging ratio: Selecting customized low-alloy steel combined with multi-directional forging processes helps ensure reasonable distribution of forgings, improves internal microstructural density, and effectively eliminates looseness and microcracks.
• Fine molds and process control: Using high-precision molds combined with temperature-controlled forging technology, key dimensional tolerances are kept within ±0.3mm, improving batch consistency; At the same time, an online dimensional inspection system has been introduced to enable real-time monitoring and traceability of the dimensional data of each forging.
• Staged controllable heat treatment: Uses a composite heat treatment process of precooling + isothermal quenching + tempering, combined with specialized tooling clamping, to keep deformation within 0.5mm and completely eliminate subsequent correction steps.
• Full-process quality traceability: From raw material entry to finished product shipment, a three-level inspection mechanism is implemented (incoming hardness/composition, process metallographic/flaw detection, final mechanical property inspection), ensuring that every forging meets the load and fatigue life indicators required by customer technical agreements.

After batch validation, after adopting the Jianing forging solution, the internal defect rate of the customer's wheel forgings dropped below 0.2%, the defect rate decreased by about 68%, the heat treatment correction process was completely eliminated, overall manufacturing costs dropped by about 15%, and the fatigue life of the entire wheel machine was extended by more than 30%, effectively supporting the improvement of the customer's product competitiveness.