Case of coil forgings at a construction machinery factory in Guangyuan, Sichuan

In the field of construction machinery, disc forgings, as key transmission and support components, have quality that directly affects the overall operational stability and operational efficiency. A construction machinery factory in Guangyuan, Sichuan, has long faced challenges such as large allowances for processing coil forgings, low material utilization rates, and fluctuations in finished product performance. Through cooperation with Jianing Forging, the factory has successfully achieved dual improvements in forging quality and production efficiency.

Customer pain points

During the procurement and use of disc forgings, the construction machinery factory mainly encountered the following issues:

• Traditional forging processes cause uneven internal structure, making subsequent machining prone to deformation or cracking, resulting in a high defect rate.
• The blank allowance is designed to be too large, which not only consumes more raw materials but also extends the machining cycle, increasing manufacturing costs.
• During mass production, different batches have poor consistency in hardness, metallographic structure, and other aspects, affecting the assembly accuracy and service life of the entire machine.
• For complex-shaped disc and cake parts (such as those with steps, grooves, or irregular outer edges), the forming capability is insufficient, requiring repeated heating and forging, resulting in low production efficiency.

Product advantages

To address these pain points, Jianing Forging provided a customized disc forging solution for a construction machinery factory in Guangyuan, Sichuan:

• Fine forming technology: Using multi-directional die forging and near-net forming processes, the forging shape closely matches the finished product drawing, reducing machining allowance and increasing material utilization by over 20%.
• Uniform microstructure control: By optimizing heating specifications and forging ratios, combined with temperature-controlled cooling, the core and surface layers are evenly coordinated, eliminating internal stress and reducing the risk of deformation during subsequent machining.
• Stable batch quality: A full-process traceability system has been established from raw material entry to finished product shipment. Each batch undergoes process verification and mechanical property testing, hardness fluctuations are controlled within ±2 HRC, and metallographic grade is maintained within grade 3.
• Efficient production cycle: Designed with dedicated molds and forging processes for typical pan cake specifications at the factory, shortening the forging cycle for single pieces by 30%, while also reducing the number of flame heating cycles, thereby lowering energy consumption and scale loss.

After practical validation, after adopting Jianing's forging solution, the final pass rate of pan forgings at the construction machinery plant increased to over 98%, the comprehensive cost per piece was reduced by about 15%, and the equipment's service life extended by 20%. Jianing Forging will continue to support partners in cost reduction, efficiency improvement, and quality improvement through process innovation and meticulous management.