In the field of automotive parts manufacturing, the quality of die forgings directly affects the vehicle's safety and service life. An auto parts factory in Bijie, Guizhou, has long faced difficulties in processing forgings: uneven internal product organization leads to insufficient fatigue life, rapid mold wear keeps production costs high, and delivery cycles struggle to meet rapidly changing market demands. To address these pain points, Jianing Forging offers comprehensive solutions from material selection to process optimization.

Case Background

This auto parts factory mainly produces chassis connectors and steering system forgings. The original supplier's die forgings had issues with coarse grains and unreasonable streamline distribution, leading to early fractures during bench testing. At the same time, the average mold lifespan is less than 3,000 pieces, and frequent mold changes cause frequent production line shutdowns, with the overall yield rate remaining at only about 85%.

Customer needs analysis

The customer requires a die forging that combines relatively high strength with good toughness, and can be adapted for large-scale continuous production. Specific requirements include: hardness stabilized between HRC 28-32, internal flaw detection meeting ASTM E112 Class 5 standard, mold lifespan extended to over 5,000 pieces, and support for small-batch rapid mold change in flexible production mode.

Jianing forging solutions

After on-site research and simulation analysis, the Jianing forging technology team adopted the following targeted measures:

• Optimizing forging temperature and deformation parameters ensures that metal flow lines evenly spread along the part contour;
• Selected high-purity alloy structural steel, combined with normalizing + quenching and tempering pretreatment processes, eliminates microstructure segregation;
• Designed multi-station precision forging dies with added high-temperature wear-resistant coatings on the surface, extending mold lifespan to 6,500 pieces;
• Introducing servo hydraulic presses and intelligent temperature control systems to achieve closed-loop forging temperature control at ±5°C, which helps ensure batch consistency.

After implementation, the factory's die forging flaw detection pass rate increased to over 98%, unit cost reduced by 12%, and delivery cycle shortened by 30%. Currently, this solution has been applied in mass production of chassis components for multiple models, with positive customer feedback.