Shanxi Jianing Forging finishing gears, valve bodies, and automotive parts fine die forging live case study, intuitively presenting high-precision die forging processing and finished product dimensional accuracy, suitable for automotive, petrochemical, and hydraulic equipment support.
A heavy automobile factory in Yuncheng, Shanxi, faced challenges such as short mold lifespan, poor dimensional stability of forgings, and low production efficiency when producing heavy truck chassis mold forgings. The forgings supplied by the factory's original supplier are prone to early cracks during continuous stamping, leading to frequent die-changing stoppages and affecting the overall production capacity. To this end, the factory collaborated with Jianing Forging to develop alloy formulations in a targeted manner and optimize forging processes, ultimately upgrading the performance of die forgings.
This heavy automobile factory has long been plagued by the following issues: First, the fatigue life of die forgings under heavy load conditions is insufficient, requiring more than two additional repairs per batch on average, increasing hidden costs; Second, the internal microstructure uniformity of the forgings fluctuates greatly, leading to unstable machining allowances and a defect rate as high as 8%; Third, suppliers have long response cycles and cannot keep pace with the factory's rapid iteration production cycle, resulting in frequent material waiting on the production line. These pain points directly affect the vehicle's assembly schedule and final delivery quality.
To address these pain points, Jianing Forging has provided a systematic solution: First, microalloying technology is used to optimize the composition of raw materials, increasing the fatigue cycle count of die forgings by about 40%, effectively suppressing early crack initiation; Second, through multi-directional forging and temperature-controlled speed control, the internal grain size of the forging is stabilized above grade 8, helping to control dimensional consistency fluctuations within ±0.3 mm; Additionally, Jianing Forging has established a rapid response mechanism, reducing conventional delivery cycles by 15% to meet the factory's flexible production scheduling needs. After batch validation, this solution helped customers reduce the defect rate from 8% to below 2%, while extending mold lifespan by more than 30% and reducing overall production costs by approximately 12%.
