A certain ship parts factory has long faced issues such as insufficient precision of key forgings, low production efficiency, and severe material waste during the shipbuilding process. Traditional processes struggle to meet the high standards of ship parts, resulting in low product qualification rates and extended delivery cycles. To address these challenges, Jianing Forging, leveraging its technical expertise in the die forging field, has customized a systematic die forging solution for this customer.

Customer pain point analysis

The shipbuilding parts factory's original production process was mainly free forging, with the following prominent issues: First, poor dimensional stability of forgings, large machining allowance, and material utilization rate below 70%; Second, the mold lifespan is short, and frequent changes affect production cycles; Third, some complex structural parts are difficult to form, requiring multiple heating and forging passes, resulting in high energy consumption and long cycles. These issues directly restrict customers' capacity improvements and cost control.

Jianing Forge's solution

To address customer pain points, Jianing Forging offers fine die forging products and supporting process optimization solutions:

• By adopting multi-directional die forging technology, complex shapes are formed in one step, reducing subsequent processing and increasing material utilization to over 90%;
• Optimized mold design and material selection, extending mold lifespan to more than twice the original level, reducing overall costs;
• Numerical simulation assists process parameter optimization, helping to ensure uniform internal microstructure of forgings and mechanical performance that meets the relatively high strength and toughness requirements of ship parts;
• We provide end-to-end quality control from material inspection to finished product delivery, helping every batch meet industry standards.

After batch validation, the ship parts factory's die forging pass rate increased from 82% to over 97%, shortened the single-piece production cycle by 40%, and reduced overall costs by about 18%. The customer stated that Jianing Forging's die forging solutions not only solved long-standing production bottlenecks but also provided reliable support for subsequent localization upgrades of ship parts.