Shanxi Jianing Forging has gathered real-world cases of wind power flange rings, ring gears, bearing rings, roller rings, and other ring landings, with a complete range of finished forging products for carbon steel, stainless steel, and alloy rings, providing reference for product selection and non-standard solutions.
A metallurgical parts factory in Zhuzhou, Hunan, has long been engaged in supporting production of key components for the metallurgical industry. During the procurement and use of ring-shaped forgings, it encountered multiple technical challenges. The factory requires high-precision, relatively high-strength ring-shaped forgings to adapt to high-temperature and high-pressure working conditions, while also demanding stable batch supply to avoid production line shutdowns caused by quality fluctuations of forgings.
This customer faced the following issues in the application of ring forgings:
1. Difficulty in controlling geometric tolerances: Under traditional processes, the roundness and flatness of forgings fluctuate greatly, resulting in uneven machining allowances and serious material waste.
2. Unstable mechanical properties: Some batches of forgings exhibit uneven hardness and low impact toughness, affecting equipment service life.
3. Long delivery cycles: Unstable upstream blank supply leads to frequent production schedule adjustments for customers' production lines.
4. Size range limitations: Customers require multiple specifications of annular forgings (outer diameter 200mm~800mm, wall thickness 30mm~100mm), but general products on the market cannot meet all requirements.
To address these pain points, Jianing Forging offers customized comprehensive solutions for ring forgings:
1. Precision Control Forging Process: Uses multi-directional upsetting + reaming composite process, combined with tire film tooling, controlling the roundness of the ring forgings within 0.5mm and flatness ≤ 0.3mm, reducing machining allowance.
2. Material Optimization Matching: Select 25Cr2MoVA or 42CrMoA materials according to customer working conditions. Through normalizing + tempering, hardness uniformity reaches within HRC 3, and impact toughness is stabilized at ≥60J/cm².
3. Flexible production scheduling: Caring Forging has built modular forging lines that support small-batch, multi-variety rapid production changeovers, shortening the delivery cycle for regular orders to 15 working days and reducing urgent orders to 7 working days.
4. Full-size coverage: We can provide ring forgings with an outer diameter of 200mm~1200mm and wall thickness of 20mm~150mm, and support for non-standard customization to meet customers' diverse specifications.
After batch supply validation, after adopting Jianing's ring forgings, the machining scrap rate dropped by about 80%, the cost per material per piece was reduced by over 12%, the continuous operation cycle of the equipment was extended to 18 months, and the pressure on spare parts inventory was reduced. The two parties have established a long-term strategic partnership to jointly develop a new generation of high-temperature resistant ring forgings.
