Shanxi Jianing Forging has gathered real-world cases of wind power flange rings, ring gears, bearing rings, roller rings, and other ring landings, with a complete range of finished forging products for carbon steel, stainless steel, and alloy rings, providing reference for product selection and non-standard solutions.
A bearing parts factory in Nanchang, Jiangxi, has long focused on the production and assembly of fine bearing parts. Its production line has strict requirements for dimensional accuracy, material uniformity, and batch stability of ring forgings. However, the company frequently encountered issues such as large deviations in the inner and outer diameters of forgings, frequent surface cracks, and uncontrollable delivery cycles during actual production, which not only affected the bearing assembly pass rate but also increased subsequent machining costs. After gaining in-depth understanding of their process bottlenecks, Jianing Forging provided a customized ring forging solution covering raw material selection, forging process optimization, and fine heat treatment, successfully helping the customer improve forging qualification rates and supply chain efficiency.
The annular forgings procured by this bearing parts factory are mainly used for the inner and outer ring blanks of rolling bearings, which must meet requirements such as low stress concentration, high wear resistance, and long-term fatigue life. The previous supplier had issues such as unstable heating temperature control and insufficient forging ratio during forging forming, resulting in band-like segregation in the internal structure of the forging and severe tool wear during subsequent turning processes. In addition, there are significant dimensional fluctuations between batches, with some radial runout exceeding drawing tolerances by more than 0.15mm, causing frequent rework in assembly processes and reducing production efficiency by about 12%. At the same time, the delivery cycle for customized orders can be as long as 45 days, which cannot meet the urgent order needs of end customers.
To address these issues, Jianing Forging provides systematic solutions from the following three dimensions:
1. Raw Material Control and Forging Process Optimization Using high-quality alloy structural steel, each batch undergoes chemical composition and inclusion inspections to help maintain material purity. In the forging stage, simulation software optimizes upsetting and punching processes, keeping forging temperatures within standard ranges to reduce scale formation. Adjust the forging ratio to a reasonable range, distribute the metal flow line evenly along the ring, effectively eliminating internal segregation.
2. Fine molds and dimensional consistency support: Design dedicated ring forging molds, combined with automatic temperature-controlled hydraulic fast forging machines, to achieve consistent deformation each time. After forging, normalizing + tempering treatments are added to refine grains and release residual stress. The final product's radial runout is stably controlled within 0.08mm, with inner and outer diameter tolerances meeting Class C precision requirements, and uniform surface hardness, leaving ample margin for subsequent finishing.
3. Agile Delivery and Quality Traceability: Establish dedicated production lines to reduce the production cycle for standard specification ring forgings to under 20 days; Urgent orders can be delivered within 15 days through expedited scheduling. Each forging comes with traceable furnace number, forging records, and inspection reports, allowing customers to check process parameters at any time for internal quality audits.
After switching to ring forgings supplied by Jianing Forging, the first-pass pass rate for the bearing parts factory increased from 85% to 96.5%, cutting tool consumption was reduced by about 30%, and overall processing costs dropped by 8%. At the same time, stable delivery cycles allow customers to flexibly schedule production and reduce inventory backlogs. The two parties have established a long-term cooperation agreement, and Jianing Forging continues to optimize process parameters based on its annual needs, helping customers maintain competitiveness in the bearing market.
