A Shanghai automation heavy factory faced issues of insufficient precision and unstable properties of annular forgings during the production of key transmission components. The forgings from the factory's original suppliers failed to meet the stringent requirements of automated assembly lines in terms of dimensional tolerances and internal organizational uniformity, resulting in excessive assembly gaps, obvious operating noise, and even affecting overall production line efficiency. To address this condition, Jianing Forging optimizes forging processes and full-process inspection, customizing highly consistent ring forgings for customers, improving assembly and lifespan challenges.

Customer pain points

The ring-shaped forgings in this automated heavy factory are mainly used for transmission structures bearing high speeds and heavy loads, requiring extremely high roundness, end-face parallelism, and internal metal flow line distribution. The original supplier's products have the following issues:

• Dimensional deviations exceeding the drawing tolerance range require manual grinding during assembly, which is time-consuming and labor-intensive;
• The forgings have microscopic defects such as looseness and segregation, which can easily lead to early fatigue failure during use;
• Poor consistency between batches and large performance fluctuations of forgings in the same order make it difficult to establish stable quality control standards.

Product advantages

After fully understanding customer needs, Jianing Forging offers targeted solutions from three dimensions: raw materials, processes, and inspection:

• Select high-quality alloy steel ingots, forge and open the billet through multi-directional upsetting and drawing, eliminating casting defects and improving material density;
• Using a fine ring rolling + heat treatment dual-control process, it helps with forging dimensional accuracy (roundness ≤0.3mm, parallelism ≤0.2mm) and uniform fine grain microstructure;
• Ultrasonic flaw detection and coordinate measuring are performed individually, and a complete inspection report is issued, helping to trace every forging.

Ultimately, the customer's overall line equipment assembly efficiency improved by about 30%, operating noise was reduced by more than 15dB, and forging service life more than doubled, earning full recognition from the customer's technical department.