Amid the tide of new energy vehicle lightweighting and industrial low-carbon transformation, the near-net shape warm forging process has become a core green technology in the wheel hub manufacturing field. Data from the “2025 Green Forging Technology White Paper” released by the China Forging & Press Association shows that this process reduces the average machining allowance of wheel hub unit forgings to 0.8-1.2mm, a significant decrease from the 2.5-3.5mm of traditional hot die forging. It directly drives a 37% drop in single-piece cutting energy consumption and a 42% reduction in tool wear, achieving a dual breakthrough in efficiency and environmental protection.
The advantages of the warm forging process stem from the integrated innovation of hot forging and cold forging technologies. By precisely controlling the processing temperature in the range of 350-800℃ and adopting a flashless closed-die forging design, the material utilization rate is increased to over 92%, and the scrap rate is reduced to below 1%, far exceeding the 70%-75% utilization rate of traditional open-die forging. Meanwhile, the metal structure becomes denser through precision forging, increasing wheel hub strength by more than 30% and reducing weight by 15-20%, which perfectly meets the dual needs of new energy vehicles for safety and lightweighting.
Leading enterprises have taken the lead in implementing this process. Jiangsu Longcheng Precision Forging adopts a composite process of warm forging and cold finishing, increasing the material utilization rate from 68% to 89%. Wuzhou Xinchun strengthens the continuity of material flow and improves product fatigue strength through warm forging technology by integrating the whole industry chain of “pipe making, forging and machining”. These practices confirm the significant value of the process in cost reduction and efficiency improvement: unit product energy consumption decreases by 20% compared with traditional hot forging, and carbon emissions are reduced by 22%.
With the intensification of policies and market upgrading, the penetration rate of this process continues to rise. In 2025, the demand for new energy vehicle wheel hub forgings accounted for 39.6%, and the penetration rate of third-generation integrated products increased to 68%, forcing the process to upgrade towards intelligence. Leading enterprises have realized full-process closed-loop control with digital twin and AI systems, improving per capita efficiency by 40%. The near-net shape warm forging process is reshaping the pattern of wheel hub manufacturing through technological innovation, injecting lasting impetus into the green and high-quality development of the industry.
Post time: Jan-27-2026
