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.
In the field of transmission machinery manufacturing, the quality of die forgings directly affects the stability and service life of equipment. A transmission machinery factory in Dingxi, Gansu, encountered issues during production with insufficient precision of die forgings and low material utilization rates, affecting overall assembly efficiency and product reliability. To address this, based on its own experience in die forging processes, Jianing Forging provided the customer with customized solutions, improving the consistency and mechanical properties of the forgings.
This case focuses on the forging processing needs of a transmission machinery factory in Dingxi, Gansu. The factory has long been engaged in the production of transmission machinery components, with high requirements for dimensional tolerances, internal structure, and batch stability of forgings. As a professional supplier in the related field, Jianing Forging was invited to assist in the development of new projects and provide full-process services from mold design to finished product delivery.
Customers face three main issues in their existing processes:
1. Large dimensional deviations in forgings lead to uneven machining allowances and a high defect rate.
2. Insufficient material utilization, excessive flash in forgings, and about 12% overconsumption of raw materials per product.
3. Significant fluctuations in mechanical properties between batches, with some products exhibiting uneven hardness after heat treatment, affecting transmission efficiency after assembly.
These issues not only increase production costs but also extend product delivery cycles.
To address these pain points, Jianing Forging started with process optimization and provided the following solutions:
- Uses fine die forging technology, computer simulation, and die correction to keep dimensional tolerances within ±0.3mm, reducing machining workload.
- Adjust the mold parting surface design and flash groove parameters to increase material utilization to over 88%.
- Standardized forging temperature control and isothermal normalizing process are introduced, helping to reduce hardness fluctuations of each batch to less than 5HB.
- Supports full-process dimensional inspection and metallographic inspection to achieve traceability of forgings.
