In the field of mining machinery, carbon steel forgings, as key components, have quality that directly affects the stability and safety of equipment operation. This case focuses on a mining machinery factory in Wuxi, Jiangsu (hereinafter referred to as "the factory"), which successfully solved a series of long-standing technical challenges in production through the carbon steel forging customization services provided by Jianing Forging.

Case Summary

The factory mainly produces mining crushing and conveying equipment, requiring mass use of carbon steel forgings as drive shafts and connectors. Forgings provided by original suppliers frequently exhibit dimensional deviations and uneven internal microstructures during processing, resulting in low equipment assembly efficiency and high rework rates, which seriously affect production progress and cost control.

Customer pain points

• Insufficient dimensional accuracy: Blank machining allowance is too large, subsequent machining is time-consuming and labor-intensive, and the finished product pass rate is below 85%.
• Unstable material properties: Some batches of forgings have large hardness fluctuations, and some develop quenching cracks, affecting service life.
• Uncontrollable delivery cycles: Due to forging process limitations, order delivery times are often delayed, causing complete machine assembly plans to be disrupted.
• Frequent surface defects: surface issues such as scale oxide, folds, and pits require additional polishing, increasing process costs.

Product advantages and solutions

To address the plant's pain points, Jianing Forging provided a systematic optimization solution from process design to production control:

• Relatively accurate forming technology: Mold simulation design is conducted based on the final part drawing, controlling blank allowances within a reasonable range, eliminating the need for rough turning steps, and significantly improving dimensional consistency.
• Material control system: Selected high-quality carbon steel round steel, each batch comes with a material report. Through forging ratio optimization and normalizing + tempering treatment, grain refinement and hardness uniformity are achieved.
• Flexible scheduling mechanism: For small-batch, multi-variety orders, a dedicated production cycle has been established, shortening standard lead times to 15 working days and urgent orders to 7 working days.
• Surface quality management: Uses high-pressure water descaling combined with shot blasting cleaning, achieving a surface roughness of Ra≤6.3μm, eliminating the need for subsequent grinding steps.

After implementation, the factory's first-pass pass rate for forgings increased to over 97%, processing efficiency increased by about 30%, and there were no delays in delivery for six consecutive months. With reliable product quality and stable delivery capabilities, Jianing Forging has become an important partner for the plant's carbon steel forgings.