In the field of building materials heavy industry, the quality and delivery cycle of large disc forgings directly affect the overall efficiency of the production line. This article takes the pan cake forging project at a building materials heavy factory in Hanzhong, Shaanxi as an example to demonstrate how Jianing Forging uses professional technology to solve customers' practical problems and deliver high-quality forgings.

Case Summary

A heavy building materials factory in Hanzhong, Shaanxi, due to a production line upgrade, needed to purchase a batch of large-size disc forgings for structural support and transmission components for key equipment. The factory had previously tried multiple suppliers but was unable to meet both machining precision and delivery time requirements.

Customer pain points

Customers face the following three main issues in actual production:

• Difficulty in controlling dimensional tolerances: disc forgings have a diameter of 1.8 meters and a thickness exceeding 300 millimeters. Traditional processes are prone to deformation after heat treatment, resulting in insufficient machining allowance for subsequent processing.
• Unstable material performance: The internal microstructural density of forgings supplied by the original supplier fluctuates significantly, with cracks appearing in some batches, affecting equipment operation safety.
• Uncontrollable delivery cycles: Due to poor multi-process flow, orders are often delayed, disrupting the factory's overall production schedule.

Product advantages

To address these pain points, Jianing Forging, relying on its mature forging process system, provided customized disc forging solutions for this project:

• Optimizing forging ratio and heat treatment process: By controlling the upset ratio and cooling rate, forging deformation is effectively reduced, keeping the finished product diameter tolerance within ±1.5mm.
• Using high-quality alloy steel billets combined with multi-directional forging technology enhances the internal density of the forgings, achieving first-class standards through ultrasonic flaw detection.
• Establishing specialized production schedules: A project team was formed to coordinate cutting, forging, heat treatment, rough processing, and inspection, reducing the delivery cycle to 25 days—about 30% lower than the industry's usual level.

In this cooperation, Jianing Forging has supplied a total of 36 disc forgings to Hanzhong Building Materials Heavy Factory. After customer acceptance, all meet the drawing requirements and have been successfully put into production line operation, earning high recognition from the customer.