In the field of construction machinery manufacturing, the quality of die forgings directly affects the overall machine performance and service life. A construction machinery factory located in Zhenjiang, Jiangsu, faced practical issues such as insufficient forging strength, poor dimensional stability, and tight supply cycles during long-term production. Through deep cooperation with Jianing Forging (hereinafter referred to as "our company"), the plant successfully resolved these production bottlenecks, achieving dual improvements in product quality and production efficiency.

Case Background

This construction machinery factory mainly produces key structural components for heavy equipment such as excavators and loaders, with die forgings used at complex connection points. As market demands for equipment lightweighting and reliable performance continue to rise, forgings provided by original suppliers are increasingly unable to meet design specifications in terms of fatigue resistance and batch consistency, leading to a rise in overall machine failure rates. At the same time, customers' production schedules are frequently adjusted, raising higher demands for the flexibility and timeliness of forging delivery.

Challenges faced by customers

• Unstable mechanical properties: Some batches of die forgings exhibit early failure during impact testing and cannot pass factory inspection.
• Excessive machining allowance: Dimensional deviations in forging blanks lead to increased machining man-hours afterward, affecting overall production capacity.
• Long response cycle: The average time from order placement to delivery is 45 days, making it difficult to meet urgent customer orders.

Jianing Forge's solution

To address these pain points, our technical team and the client's engineering department have jointly tackled the issues, providing customized solutions from three aspects: materials, processes, and services:

• Material optimization: Using microalloying formulas to improve ductility while maintaining forging strength, and implementing rigorous heat treatment processes to ensure consistent performance.
• Fine Die Forging Technology: Utilizes multi-station die forging and near-net forming processes, keeping machining allowance within 1.0mm per side, reducing subsequent cutting volume.
• Flexible scheduling system: Established dedicated material preparation inventory and rapid mold change processes, reducing the delivery cycle for standard parts to 15 days and urgent orders to 7 days.

Implementation Results

After three months of trial production and mass supply, customer feedback is as follows:

• The mechanical performance pass rate of forgings has remained stable above 99.5%, with no further early failure issues.
• Machining efficiency improved by about 20%, and the overall manufacturing cost per piece decreased by about 12%.
• Supply chain response speed has significantly improved, reducing customer production line downtime by 80%.

Currently, this construction machinery factory has designated our company as a long-term preferred supplier for die forgings, and several new machine models have directly adopted our recommended forging solutions. This collaboration not only solves the customer's practical problems but also provides reusable reference experience for high-quality applications of die forgings in the construction machinery industry.