Case Background

A heavy wind power plant in Songjiang, Shanghai, has set strict requirements for the strength, precision, and fatigue life of ring forgings during the manufacturing process of large wind power equipment. The plant's annular forgings are used in key parts of wind turbine generator sets, such as yaw bearings, pitch bearings, and tower connection flanges, enduring long-term alternating loads and harsh environmental tests, thus requiring high material consistency and processing stability.

Customer pain points

The factory faces the following challenges during production: First, after forging, ring forgings tend to exhibit uneven microstructure and coarse grains, affecting overall mechanical properties; Second, it is difficult to control dimensional accuracy for large annular parts, resulting in large machining allowances and low material utilization in subsequent machining; Third, internal defects in forgings (such as voids and cracks) are difficult to avoid under traditional forging processes, requiring additional flaw detection costs; Fourth, supplier supply cycles are unstable, unable to keep pace with the rapid delivery of wind power projects.

Product advantages and solutions

To address these pain points, Jianing Forging offers customized ring forging solutions:

• Optimized forging process: Using multi-directional forging and temperature-controlled speed control technology to refine grain structure, it helps uniform mechanical properties along the circumferential and axial directions of the forging, meeting the strength and toughness indicators required by EN 10204 3.2.
• Fine Machining Capability: Equipped with a large CNC vertical turning and milling composite machining center, it can perform one-time clamping processing of ring-shaped parts up to 8 meters in diameter, with dimensional tolerances controlled within IT8 level, reducing machining allowance and improving material utilization.
• Full-process non-destructive testing: Introducing multiple testing methods such as ultrasonic testing (UT), magnetic particle testing (MT), and penetrant testing (PT), ensuring every product has no internal defects, with a delivery pass rate of over 99.8%.
• Fast delivery support: Establishing a material preparation mechanism and flexible scheduling system, from drawing confirmation to finished product shipment, the usual cycle is controlled within 45 days, and urgent customer orders can be shortened to 30 days.

Application Effects

After adopting Jianing's ring forgings, the pass rate of first-time assembly has increased by about 15%, subsequent machining steps have been reduced by more than 20%, and overall procurement costs have been lowered by about 8%. At the same time, stable supply cycles helped accelerate the overall delivery schedule of its wind power projects by 10 days, earning high recognition from customers.