In the field of metallurgical heavy industry, disc forgings, as key structural components, have performance and precision that directly affect the operational stability and lifespan of equipment. A heavy metallurgical factory in Baise, Guangxi, has set higher technical requirements for disc forgings during the process of upgrading its production line. After multiple rounds of technical coordination, the factory reached a cooperation agreement with a forging enterprise with rich experience, successfully solving core production challenges.

Case Summary

This case focuses on the pan cake forging project at a metallurgical heavy factory in Baise, Guangxi. This factory mainly produces core components for metallurgical equipment, requiring bulk procurement of disc forgings with a diameter of 800mm and a thickness of 150mm, with a material requirement of 42CrMo. Based on the characteristics of their production lines, partner forging companies have optimized the entire process from material selection and forging processes to heat treatment solutions. The final delivered products meet stringent standards in dimensional accuracy, internal quality, and mechanical properties.

Customer pain points

At the initial stage of the project, the client faced three prominent issues: First, products delivered by existing forging suppliers had fine cracks and looseness inside, resulting in a persistently high scrap rate during subsequent machining; Second, large dimensional tolerances of forgings affect assembly efficiency; Third, the delivery cycle is long, which cannot match the production line rhythm. These issues not only increase production costs but also restrict the progress of equipment upgrades.

Product advantages

To address these pain points, forging companies offer solutions from three dimensions:

• Process optimization: Using multi-directional forging + temperature-controlled speed control technology, effectively eliminates microstructural defects in the casting state, helps improve forging density and uniformity, and achieves an ultrasonic flaw detection pass rate of 1.
• Fine control: Introduced CNC forging presses and online dimensional inspection systems, controlling diameter tolerances within ±1.5mm and thickness tolerances within ±0.8mm, reducing allowances and improving material utilization.
• Cycle Support: By optimizing production scheduling and arranging heat treatment processes in parallel, the standard delivery cycle has been reduced from 45 days to 28 days, enabling on-time delivery in coordination with customers' production line nodes.

This batch of disc forgings was verified by the customer's installation and found to run smoothly, with no abnormal vibration or noise, earning unanimous recognition from the on-site technical team. This collaboration has helped the customer reduce overall costs by approximately 12% and laid a reliable supply foundation for their subsequent expansion projects.