Case Summary

A hydraulic machinery factory in Chuxiong, Yunnan, has long faced problems such as low forging efficiency, low material utilization, and difficulty in product consistency during the production of pan forgings. The factory's original process relied on traditional open-die forging, resulting in large machining allowances, costly subsequent machining time, and significant quality fluctuations between batches, which severely restricted capacity improvement and cost control. To address these pain points, Jianing Forging provides customized disc forging solutions.

Customer pain points

The main issues encountered by this hydraulic machinery factory in disc forging production include:

• Severe material waste: Under traditional open-die forging processes, disc forgings require a large allowance for processing, with material utilization below 70%, increasing raw material costs.
• Low production efficiency: The forging cycle for single pieces is long, requiring multiple rounds of heating and repeated repairs, making it impossible to meet the delivery times for bulk orders.
• Unstable dimensional accuracy: Relying on manual operation to control dimensions, large deviations in outer diameter and thickness between batches cause some finished products to require secondary rework.
• Heavy subsequent processing burden: The surface of forgings is not very flat, requiring a large amount of material to be removed during machining, which extends the overall production cycle.

Product advantages and solutions

To address these pain points, Jianing Forging optimized mold design and forging processes to provide targeted solutions for a hydraulic machinery factory in Chuxiong, Yunnan:

• By adopting a closed die forging process, flash and allowance are reduced, material utilization is increased to over 90%, directly lowering raw material consumption.
• Through multi-station precision forging, single-piece forging efficiency is improved by about 40%, without the need for repeated heating, reducing energy consumption and processing time.
• Strictly control die clearance and forging temperature ensures that the outer diameter tolerance of disc forgings is kept within ±0.3mm, and thickness tolerances within ±0.2mm, significantly improving batch consistency.
• Optimizing the post-forging heat treatment process helps ensure uniform internal product structure, and the comprehensive mechanical properties meet the requirements of hydraulic machinery factories, reducing subsequent machining allowance by 30%.

After implementing this plan, customers reported that forging costs were reduced by about 15%, delivery cycles shortened by 20%, and product pass rates remained stable above 98%. Jianing Forging continues to provide reliable custom disc forging services for the hydraulic machinery industry, helping customers enhance their competitiveness.