Case Background

A valve parts factory in Rongchang, Chongqing, has been seeking stable and efficient supply channels for forgings when mass-producing key high-pressure valve components. The factory's products are mainly used in petroleum and chemical pipeline systems, with high requirements for the internal quality and dimensional consistency of forgings. To address this, our company provides customized die forging solutions tailored to their actual needs.

Problems faced by customers

The original forging process had the following shortcomings: First, the internal structure of the forging was not dense enough, leading to microcracks after machining and affecting sealing performance; Second, large dimensional deviations, requiring multiple repairs for the same batch of products, seriously affecting production cycles; Third, material utilization is too low, with excessive burrs, resulting in cost waste; Fourth, during large-scale deliveries, quality fluctuations between batches are obvious, increasing the difficulty of subsequent inspections.

Solutions and product advantages

To address these issues, our company optimized four stages: mold design, heating process, forging parameters, and subsequent heat treatment. By adopting multi-station precision forging technology combined with finite element simulation analysis, the forging is formed closer to the final dimensions, reducing subsequent machining allowances. At the same time, strict control of initial and final forging temperatures helps improve metal fluidity and prevents overheating. After forging, an isothermal normalizing process is used to achieve uniform and refined grain sizes, enhancing overall mechanical properties. The final delivered die forgings have dimensional tolerances stabilized within ±0.3 mm, material utilization rates have increased to over 82%, and batch pass rates have exceeded 98%.

Product features

For valve accessory die forgings, our company has summarized the following core features:

• Fine forming: The mold uses five-axis machining combined with wear compensation design to ensure dimensional consistency during mass production.
• Uniform microstructure: Through temperature-controlled forging and isothermal normalization, equiaxed crystalline structure is obtained without strip segregation.
• High material utilization: optimized flash groove structure, with burr content controlled within 8% of billet weight.
• Fast delivery: Standard parts are kept in stock, and the production cycle for non-standard molds is shortened to 10 working days.

Product Parameters (Typical Valve Fitting Die Forgings)

• Material grade: AISI 4140 / 42CrMo (can be adjusted according to customer requirements)
• Weight range: 0.5 kg – 15 kg
• Dimensional tolerance: ±0.3 mm (key dimensions)
• Surface condition: shot peening treatment, surface roughness Ra ≤ 6.3 μm