Case Summary

A mining machinery factory in Xuzhou, Jiangsu Province has long purchased shaft forgings for key equipment such as crushers and conveyors. Due to the harsh mining operating environment, shaft forgings must endure frequent impacts, heavy loads, and wear. Products provided by the original supplier frequently experience breakage and deformation during continuous operation, seriously affecting the overall efficiency of the equipment and production continuity.

Customer pain points

The core pain points faced by the plant include: insufficient fatigue life of shaft forgings (cracks appear in an average of just 3 months), excessive heat treatment deformation caused by uneven internal material microstructure, and assembly difficulties caused by large dimensional tolerances in finished products. In addition, bulk supply cycles are unstable, often causing production stoppages due to delayed arrivals.

Product advantages

To address these pain points, Jianing Forging has systematically optimized everything from material selection and process design to delivery services:

• Custom material formulation: Made with high-purity alloy steel (such as 40CrNiMoA), which reduces non-metallic inclusions through vacuum degassing, thereby improving impact toughness and fatigue strength.
• Fine forging process: Applying multi-directional forging and temperature-controlled forging technologies to refine grain structure, eliminate forging flow disorder, and achieve new standards for internal density and consistency of forgings.
• Full-process heat treatment: Using quenching and tempering + surface quenching composite process, strictly controlling quenching transfer time and tempering temperature, hardness uniformity is kept within ±2 HRC, effectively suppressing deformation.
• Dimensional and inspection support: Relying on CNC turning and grinding lines, key dimensional tolerances are stabilized within IT6 level; Combined with ultrasonic flaw detection, magnetic particle testing, and mechanical performance testing, it achieves a low defect rate before leaving the factory.
• Rapid response mechanism: Establishing raw material safety stock and flexible scheduling systems, compressing standard lead times to 15 days and urgent orders within 7 days, strongly supporting customers' production rhythms.

Application Effects

After customers use shaft forgings provided by Jianing Forging, the average service life has increased from 3 months to over 12 months, equipment failure rates have dropped by about 60%, and annual maintenance costs have been reduced by over 40%. At the same time, assembly efficiency has significantly improved due to enhanced dimensional consistency, with production plan fulfillment rates rising to 98%. This case demonstrates that through systematic technical optimization, shaft forgings can better adapt to the harsh working conditions of mining machinery, creating long-term value for customers.