Shanxi Jianing Forging includes real-life engineering cases of tube sheets, flanges, and various round disc forgings. The finished products of carbon steel and stainless steel disc forgings are clearly photographed, directly reflecting the processing precision of the forgings and the effectiveness of pipeline compatibility.
A transmission equipment factory located in Baishan, Jilin, requires a batch of high-precision disc forgings for the core load-bearing parts of a critical transmission system during the manufacturing process of large transmission components. This forging sets strict requirements for internal microstructural density, mechanical property consistency, and machining allowance control, representing a typical high-quality customized forging demand.
The customer encountered multiple challenges in the early stages of production:
1. Traditional open-die forging processes struggle to stably control the flatness and parallelism of disc forgings, resulting in large machining allowances, low material utilization, and relatively high overall costs.
2. Internal circulation disorder or loose defects in forgings are prone to affecting the fatigue life and reliability of transmission components.
3. Large fluctuations in mechanical properties between different batches cannot meet the unified safety factor requirements for equipment.
4. Long delivery cycles, making it difficult to keep pace with customers' continuous production schedules.
To address these pain points, Jianing Forging offers customized disc forging manufacturing solutions:
1. Fine Die Forging Process: Utilizes multi-station closed die forging technology, which improves the dimensional accuracy of forgings, reduces machining allowance by about 30%, and enhances the distribution of metal streamlines, resulting in a more uniform internal structure of the forging.
2. Optimized heat treatment control: By setting relatively precise parameters through normalizing + quenching and tempering processes, it helps forgings reach the customer's performance range for hardness and toughness, resulting in good batch stability.
3. Full-process inspection support: From raw material entry to finished product shipment, ultrasonic flaw detection and hardness testing are implemented to eliminate internal defects and provide detailed inspection reports.
4. Flexible production scheduling mechanism: Adjust production plans flexibly based on customer order priorities, shortening routine delivery cycles by about 20% and strongly supporting customers' assembly progress.
Ultimately, the transmission equipment factory successfully completed the batch delivery of the disc forgings, with subsequent installations running smoothly. The customer recognized Jianing Forging's technical capabilities and delivery service.
