Shanxi Jianing Forging can process large-diameter pressure vessel shell forgings made of carbon steel, stainless steel, and alloy steel. The station has a wealth of real-world cases of cylinder forging, fully demonstrating the forging capabilities of large-size cylinders and the corrosion-resistant results of finished products.
A metallurgical parts factory in Zhongshan, Guangdong, ordered a batch of cylinder forgings for production needs. These parts are used in key parts of metallurgical equipment and require high material strength, internal structural uniformity, and dimensional accuracy. Due to unstable processes from the original supplier, products often develop internal cracks and loose structures, leading to frequent equipment failures and affecting production efficiency.
1. Unstable internal quality: Multiple flaw detection tests have revealed microcracks and non-metallic inclusions in the forging, which cannot meet the long-term high-temperature and high-pressure requirements of metallurgical equipment.
2. Insufficient dimensional accuracy: The tolerance range between the inner and outer diameters of the boulder forgings is too large, making it difficult to control subsequent machining allowances, resulting in material waste and extended machining cycles.
3. Long delivery cycles: The original supplier's process is complicated, with lengthy time from material preparation to finished product delivery, making it difficult to match the customer's urgent order schedule.
4. High technical communication costs: Suppliers have a limited understanding of the special standards in the metallurgical industry, and repeated adjustments during the trial production phase increase customers' time and labor costs.
To address these issues, Jianing Forging offers the following customized solutions:
1. Optimized forging process: Using multi-directional forging and temperature-controlled forging technology, combined with intermediate annealing processes, effectively eliminates internal stress, improves microstructure uniformity, and achieves a flaw detection pass rate of over 98%.
2. Fine molds and CNC machining: Design specialized tooling fixtures and coordinate with CNC lathes for rough and fine machining, keeping the dimensional tolerances of the cylinder forgings within ±0.5mm to reduce waste of allowance.
3. Flexible Scheduling Mechanism: Establish a rapid response production scheduling system, shorten standard delivery cycles to under 25 days, and provide expedited services for urgent orders.
4. Full-process technical integration: Senior engineers communicate directly with the client's technical department, preemptively digest drawing requirements, develop personalized forging plans, and reduce trial and error.
Ultimately, the metallurgical parts factory adopted the barrel forgings made by Caring. No internal defects were found during subsequent use, the equipment ran smoothly, and machining efficiency improved by about 20%, earning high customer recognition.
