In Kunming, Yunnan, a mining parts factory has long relied on imported carbon steel forgings for replacing components in its core equipment. Due to the harsh mining environment, the requirements for forgings' strength, wear resistance, and fatigue life are extremely high. The factory has repeatedly experienced equipment shutdowns due to forging quality issues, seriously affecting production efficiency and increasing maintenance costs. To address this situation, the plant partnered with Jianing Forging, which provided customized carbon steel forging solutions.

Customer pain points

The main challenges faced by the mine parts factory include:

• Existing suppliers have large performance fluctuations between batches of carbon steel forgings, and some forgings show early cracks or deformation under heavy load conditions, resulting in frequent unplanned equipment shutdowns.
• The original forgings had insufficient dimensional tolerance control, requiring additional machining during installation, which extended maintenance cycles and increased labor costs.
• The operating environment of mining equipment contains dust and moisture, and the surface corrosion resistance of ordinary carbon steel forgings is insufficient, resulting in a service life far below expectations.
• Imported forgings have long procurement cycles, are expensive, and cannot be specifically optimized based on actual equipment operating parameters, resulting in contradictions of redundancy or insufficient performance.

Product advantages

To address these pain points, Jianing Forging offers the following customized solutions:

• By selecting high-quality carbon steel materials and accurately controlling forging temperature and deformation processes, the internal structure of the forging becomes uniform and dense, thereby improving fatigue strength and toughness. Third-party testing shows that product performance indicators meet and exceed the requirements for mining equipment use.
• By combining fine molds with CNC machining, key dimensional tolerances are kept within ±0.3mm, enabling forgings to be installed directly without secondary processing, greatly reducing maintenance time.
• The surface of the forging is treated for rust prevention and densification steps are added during the process, effectively reducing microscopic surface defects, improving corrosion resistance in humid environments, and extending service life.
• Based on the equipment load spectrum and working condition data provided by the customer, the structural shape and fiber flow direction of the forging are optimized to avoid stress concentration, while heat treatment parameters are adjusted to achieve a reasonable match between hardness and toughness, ensuring the forging maintains stable performance under heavy load impact.

After batch delivery verification, the equipment failure rate of the mine parts factory has significantly decreased, the spare parts replacement cycle has been extended by more than 30%, and overall maintenance costs have been effectively controlled. Jianing Forging continues to provide the plant with stable carbon steel forging products, helping its production operations to be smoother and more efficient.