In the field of heavy construction machinery manufacturing, the performance of barrel forgings, as key structural components, directly affects the service life of equipment and operational safety. Recently, Jianing Forging provided a customized tube forging solution for a construction machinery factory in Yingkou, Liaoning, successfully solving technical challenges related to its core components.

Case Summary

This construction machinery factory mainly produces large excavators, loaders, and other equipment. Its core tube components have long relied on external procurement, but they face issues such as insufficient strength and uneven internal organization, which leads to frequent early failures under harsh working conditions. Based on its equipment conditions and assembly requirements, Jianing Forging has developed specialized tube forgings, and after batch application and validation, the results have improved significantly.

Customer pain points

The main issues customers encounter when using cylinder forgings include: first, insufficient raw material purity, inclusions, and affecting fatigue life; Second, insufficient forging ratio and low structural density, leading to reduced impact resistance; Third, controlling dimensional tolerances is difficult, resulting in uneven machining allowances and increased machining costs; Fourth, poor compatibility of heat treatment processes, making it difficult to balance hardness and toughness, and some workpieces may crack after welding.

Product advantages

To address these pain points, Jianing Forging offers systematic solutions:

• Selected raw materials: High-purity steel ingots smelted using electroslag remelting technology, strictly controlling harmful element content to support matrix quality from the source.
• Optimizing forging processes: Through multi-heat, large deformation free forging and rounding processes, the upset ratio can reach industry recommendations, fully breaking the cast structure and obtaining uniform and fine grain structures.
• CNC for more accurate machining: equipped with large CNC ring grinding machines and specialized tooling, achieving more precise control of outer diameter, inner holes, and wall thickness, with improved allowance uniformity.
• Customized heat treatment: Based on the customer's welding process characteristics, normalizing + tempering or quenching and tempering treatment parameters are set, enabling the barrel forgings to achieve good toughness while also being weldable.

After rigorous inspection, ultrasonic flaw detection of this batch of cylinder forgings met the JB/T 5000.15-2007 Class II standard, with hardness fluctuations controlled within ±HB10. After delivery, customers reported smooth assembly, a welding pass rate of 99%, and no early cracks or deformation issues after equipment operation.

Jianing Forging has mature technical expertise in the field of tube forgings, and can provide one-stop services from material selection, simulation, manufacturing, to inspection according to users' different load conditions, connection methods, and welding requirements. Whether for small-batch single-piece or large-scale production, it supports stable and reliable delivery quality.