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 automotive parts manufacturing, the quality of die forgings directly affects the vehicle's safety and service life. An automotive parts factory in Sanmenxia, Henan (hereinafter referred to as "the factory") has long been engaged in the production of chassis structural components, but in recent years has faced multiple challenges including low raw material utilization, uneven internal organization of forgings, and tight product delivery cycles. To address these pain points, Jianing Forging customized die forging solutions, optimizing forging processes and mold design to help the plant achieve stable mass production.
The factory mainly produces key die forgings such as automotive steering knuckles and control arms, with an annual output of over 100,000 pieces. The original process had issues such as high material loss rates, excessive forging allowance, and persistently high subsequent machining costs. At the same time, some complex structural parts are prone to circulation disorder, folding, and other defects during forging, making it difficult for product pass rates to exceed 85%.
1. Low material utilization: Under the original process, the utilization rate of bar stock is less than 70%, and a large amount of raw material is wasted during trimming and flashing processes.
2. Unstable internal quality: The microstructure density of the forging is uneven, with some areas showing looseness or coarse grains, which affect fatigue life test results.
3. Short mold lifespan: Frequent mold changes disrupt production cycles, with a single set of molds capable of completing about 3,000 products, seriously affecting capacity.
4. Tight delivery cycles: From raw to finished product requires multiple processes, with a total delivery time exceeding 15 days, unable to meet OEM bulk orders.
Jianing Forging has provided the following technical solutions to address these pain points:
· Using a refined pre-forging + final forging composite process, the billet shape is optimized through finite element simulation, increasing material utilization to over 82% and reducing waste generation.
· Introducing temperature-controlled forging technology, deformation rate is controlled within the 900°C-980°C range, grain refinement, and internal microstructure testing has reached Grade II or above standards.
· Custom higher-strength mold steel, combined with surface nitriding treatment, extends mold lifespan to 8,000 pieces per set, reducing mold replacement frequency.
· Optimized production scheduling by using near-local blank delivery and rapid mold change (SMED) solutions, compressing the comprehensive production cycle for single pieces to under 8 days.
Currently, the factory has achieved a stable monthly supply of over 8,000 units, maintaining a product qualification rate of 97%, and reducing customers' overall costs by about 12%.
