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.
During the long-term production process, a certain construction machinery parts factory imposed stricter requirements on the performance and stability of key forgings. To improve component quality and reduce overall costs, the factory partnered with Jianing Forging to jointly promote the optimization and upgrading of die forgings. With mature forging techniques and extensive industry experience, Jianing Forging provided targeted solutions to address issues exposed during the use of original forgings.
Original die forgings have the following shortcomings in practical applications: First, the internal microstructure density of the forgings is uneven, causing some parts to develop early cracks under fatigue conditions; Second, dimensional accuracy control is not stable enough, resulting in large machining allowances for subsequent machining, which increases material waste and processing time; Third, the surface oxidized decarburized layer is too thick, affecting subsequent heat treatment results and the durability of the final product. Additionally, the parts manufacturer hopes to optimize forging weight while maintaining performance to adapt to the new generation of lightweight machine designs.
To address these pain points, Jianing Forging has systematically optimized from three dimensions: materials, processes, and inspection: on the material side, it selects rigorously selected high-quality alloy steel billets and adjusts the microalloy composition ratio to improve the overall mechanical properties of the forgings; On the process side, a combination of multi-directional die forging and fine die forging is adopted, combined with computer simulation, optimizing mold cavity design and forging temperature profile, making the metal flow distribution more reasonable, internal structure more uniform and dense, while keeping dimensional accuracy within ±0.3mm, thereby reducing the machining allowance for subsequent processes; On the inspection side, the introduction of ultrasonic flaw detection combined with metallographic analysis for quality monitoring helps reduce the internal defect rate of each batch to below industry norms. The final delivered forgings showed improvements in fatigue life, dimensional consistency, and surface quality, while reducing weight by about 5%, helping the customer achieve the overall machine weight reduction goal.
