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.
A petrochemical parts factory in Lu'an, Anhui, has long faced issues of raw material performance fluctuations and insufficient processing accuracy for key connectors used under high temperature and high pressure conditions. The batch quality of the original forging supplier products at the factory was unstable, resulting in excessive clearance during assembly, affecting sealing reliability, and maintaining a high frequency of equipment maintenance.
The customer mainly faces three major challenges: First, the internal microstructure density of the forging is insufficient, making microcracks prone to occur under long-term alternating loads; Second, poor product dimensional consistency, with large dispersion in fit tolerances among different units within the same batch, increasing on-site commissioning costs; Third, traditional hot processing processes cause the surface decarburization layer to become thicker, reducing the surface hardness and corrosion resistance of components, thereby affecting their service life.
Relying on a mature die forging process system, Jianing Forging provides a systematic optimization solution tailored to the special working conditions of this petrochemical component: First, it adopts a fully enclosed die forging technology with relatively accurate temperature control, effectively improving the metal flow line continuity, making the internal structure of the forging more uniform and dense, thereby enhancing fatigue resistance; Second, digital mold design and batch shaping processes are introduced to control key dimensional tolerances within ±0.15mm, achieving high interchangeability within the same batch of products; Finally, by combining protective atmosphere heating with rapid final forging, the surface decarburization layer thickness is reduced to below 0.08mm, enhancing the component's surface wear resistance and corrosion resistance. After batch delivery validation, this solution helped customers extend the average point between failures by about 40% while reducing on-site assembly rework rates.
