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.
In the field of hydraulic heavy industry equipment, the quality of die forgings directly determines the stability and safety of equipment operation. The die forging solution provided by Jianing Forging to a hydraulic heavy factory in Langfang, Hebei, successfully helping the customer overcome long-standing production bottlenecks and achieving dual improvements in efficiency and quality.
This hydraulic heavy factory is located in Langfang, Hebei, and mainly produces large hydraulic presses and supporting components. Due to the harsh service conditions of these products, the strength, toughness, and fatigue life of key die forgings are extremely demanding. During long-term production, customers have found that the original supplier's forgings frequently exhibit internal microcracks and dimensional deviations during batch use, leading to higher equipment failure rates and persistently high maintenance costs. After extensive evaluation, the factory ultimately chose to collaborate with Jianing Forging to customize and develop reliable performance die forgings that meet its stringent standards.
1. Unstable material properties: The chemical composition and mechanical properties of forgings vary greatly between batches, making it difficult to meet hydraulic heavy industry's requirements for material consistency.
2. Inaccurate control of machining allowance: Excessive or uneven allowance in the blank of the forging mold leads to difficulties in subsequent machining, low material utilization, and increased manufacturing costs.
3. Insufficient fatigue life: Under cyclic high-pressure conditions, the original forgings are prone to early fatigue cracks, severely shortening the equipment overhaul cycle.
4. Uncontrollable delivery cycle: Because process parameters rely on experience, production schedules are often disrupted, affecting customers' complete machine assembly schedules.
To address these pain points, Jianing Forging provides systematic solutions from three dimensions: materials, processes, and inspection:
1. Material Customization and Constant Temperature Forging: According to the special working conditions of hydraulic heavy industry, optimized alloy structural steel is selected. By strictly controlling the smelting and forging temperature range, the internal structure of the forging is uniform and fine, and performance deviations between batches are kept within 5%.
2. Fine mold and CNC machining allowance design: Using 3D simulation technology to optimize mold cavities, and designing allowance distribution based on customer machining needs, the blank allowance is reduced by more than 20%, thereby lowering subsequent cutting workload.
3. Full-process stress control: After forging, multi-stage controllable cooling and stress-relief tempering processes are added to eliminate internal stress, increasing the fatigue life of forgings under simulated conditions by more than 40% compared to the original plan.
4. Intelligent Production Scheduling: Based on order data and process parameter libraries, it achieves full-process visual control from material input to finished product shipment, shortening routine delivery cycles by about 30%, and guaranteeing traceable inspection reports for each batch of forgings.
