In the field of heavy industrial equipment, shaft forgings, as key transmission components, have quality that directly affects the safety and stability of equipment operation. A heavy factory in Liaocheng, Shandong, faced multiple technical challenges during mass production of large shaft forgings. Jianing Forging, relying on solid process experience and customized services, provided a reliable solution.

Case Overview

This heavy factory mainly produces mining machinery and lifting equipment, requiring shaft forgings with complex specifications and strict requirements for material strength, dimensional accuracy, and surface quality. Previously, partner suppliers were unstable in terms of delivery cycles and product consistency, resulting in frequent production line debugging and high maintenance costs.

Customer pain points

1. Material performance fluctuations: Some batches of shaft forgings have uneven hardness after heat treatment, affecting the fit of the assembly;
2. Difficulty in controlling machining allowances: Deformation after rough turning exceeds expectations, increasing subsequent finishing time and scrap rate;
3. Limited delivery times: In multi-variety, small-batch order models, traditional production scheduling struggles to meet urgent orders;
4. Incomplete Testing System: Lack of fully traceable quality records creates risks for customer acceptance.

Solutions and product advantages

To address these pain points, Jianing Forging has optimized the entire chain of services from raw material procurement to finished product delivery:

• Material control: Selected high-quality alloy steel billets and batch re-inspected chemical composition and low-poly microstructure upon incoming shipment, supporting uniform performance from the source.
• Process optimization: Uses multi-heat forging combined with a reasonable deformation ratio design to reduce stress concentration; Strict temperature control during subsequent quenching and tempering helps maintain a stable hardness gradient.
• Precision machining: Reserve relatively accurate allowances, coordinate semi-precision and finishing processes to stably control dimensional tolerances within the IT7 level required by customers.
• Flexible Scheduling: Established dedicated production lines and emergency response mechanisms, shortening routine order delivery cycles by 20%, with urgent orders completed in as little as 7 days.
• Quality traceability: Each shaft forging is marked with an independent batch number, supporting full-process data queries from billet to finished product, making it convenient for customers to inspect the warehouse.

After actual mass production validation, this solution has increased the first-pass pass rate of customers' shaft forgings to over 98%, and reduced production line changeover time by about 30%. Jianing Forging, with robust process capabilities and an efficient collaborative model, continuously provides reliable support for shaft forgings in the heavy equipment industry.