We do assist with design modifications to optimize the steel forging process of close-die forging parts.

1. We Understand the Client' Requirements

• Technical Specifications: Work closely with the clients to understand their detailed specifications, including material properties, mechanical performance requirements, tolerances, and surface finishes.

• Application Context: Consider how the parts will be used in the buyer's industry, such as automotive, construction machinery, or industrial machinery, and optimize accordingly for durability, strength, weight, and cost.

2. We Do Material Selection

• Optimize Material Choice: Select the best steel grade based on the final part's application. High-performance steel alloys may be required for specific applications. Evaluate the material’s flowability, strength, hardness, and heat treatment response.

• Consider Global Standards: Clients from different regions may have different standards (e.g., ASTM for the US, DIN for Europe, JIS for Japan). Ensure the material complies with local standards for metallurgy, heat treatment, and testing.

3. We Design for Manufacturability

• Simplified Geometry: Minimize design complexity while maintaining functionality. Designs with less sharp corners or undercuts can reduce strain on dies and material flow, improving forging results.

• Optimize Part Shape: Ensure that the part design allows for uniform material flow during the forging process, which minimizes defects such as cracks or voids. Ensure draft angles and uniform thickness where possible.

• Eliminate unnecessary features: Avoid designing features that cannot be forged or that would require costly tooling.

4. Die Design Optimization

• Improved Die Design: Design forging dies to ensure optimal material flow, reduce die wear, and improve product quality. Use advanced software like Finite Element Analysis (FEA) to simulate the forging process and predict issues.

• Thermal Management: Close-die forging generates significant heat, so optimize die cooling channels and consider thermal treatments to extend die life.

• Die Material: Use materials for the dies that have high heat resistance, toughness, and wear resistance, such as H13 steel, to ensure longevity and quality.

5. We Do Process Control and Simulation

• Forging Simulation Software: Use software like DEFORM, Forge, or Simufact to simulate the forging process before physical production. This helps predict defects like underfill, flash, or cracking and allows for adjustments in design or process.

• Process Monitoring: Use sensors and data analytics to monitor temperature, pressure, and strain in real-time during the forging process. This can help adjust parameters like forging force, temperature, and die speed for optimal results.

6. Heat Treatment and Surface Finishing

• Post-Forge Heat Treatment: Depending on the steel type, we may need to modify the heat treatment process to achieve the desired mechanical properties (e.g., quenching, Carbon Case hardening,tempering, annealing).

• Surface Finish: Depending on the application, the surface finish may need optimization. We use techniques such as shot peening, grinding, or polishing to enhance fatigue resistance and appearance.

7. Quality Assurance

• Testing and Inspection: Ensure that parts undergo appropriate non-destructive testing (NDT), dimensional inspection, and mechanical property testing (e.g., tensile strength, hardness) to meet international standards.

• Tolerances and Fitment: Collaborate with the clients to ensure that the parts meet tight tolerances and that the forging process does not result in unnecessary deviations that would affect fitment.

8. We Do Cost Optimization

• Process Efficiency: Strive to improve efficiency in the forging process by minimizing scrap, optimizing die life, and reducing cycle times. Lean manufacturing principles like Six Sigma or Kaizen can be applied to streamline operations.

• Tooling Cost: Balance tooling cost with production volume—large international clients typically require economies of scale, so consider a solution that provides a good return on investment for both the buyer and our company.

9. The Collaborative Feedback Loop

• Frequent Communication: We establish continuous feedback loop with our international clients to ensure we are meeting their evolving needs. Sharing prototypes, offering samples for testing, and incorporating their feedback into the design and production process is crucial for long-term partnerships.

• Prototyping and Testing: We offer rapid prototyping and testing services to demonstrate how the design changes affect product performance and manufacturing feasibility before large-scale production.

10. Adapt to International Market Needs

• Compliance and Certifications: Ensure that the products comply with relevant international standards, such as ISO, ASTM, and SAE standards, to meet clients' expectations.

• Customization for Regional Markets: Be aware of regional differences in material preferences, application requirements, and quality expectations. Tailor designs accordingly to address local market demands.

11. Sustainability Considerations

• Eco-friendly Manufacturing: Big global clients are increasingly concerned with sustainability. We work to improve energy efficiency in the forging process, reduce waste, and use environmentally friendly materials where possible.

• Recycling and Reuse: We introduce recycling initiatives for scrap metal and consider the life cycle of the products from design to end-of-life.