Shafts, rollers, and rolls used in metallurgical machinery and large vehicles are subjected to significant mechanical torsion stresses, vibrations, and abrasive wear during operation. In certain cases, these components operate under high-temperature and high-humidity conditions. Therefore, to ensure their long-term, failure-free operation, it is essential to carefully select heat-resistant and corrosion-resistant tool steels, as well as to strictly adhere to the prescribed manufacturing processes. Critical forgings, such as large shafts, are typically produced through cogging on hydraulic forging presses, with pre-deformation heating and post-deformation heat treatment playing crucial roles, depending on the steel grade. This paper analyzes the causes of operational failures of components such as the “Holder,” “Mandrel,” “Roller,” and “Shaft,” which are manufactured from carbon steel (C45) and alloyed steel grades (Cr–Mo–W, C–Cr–Ni–Mo) using hydraulic forging presses. By examining the materials and the manufacturing processes, the study establishes the relationship between failures and quality indicators influenced by metallurgical and technological factors. The research methods employed include spectral chemical analysis, ultrasonic testing, and metallography. The study underscores the importance of ensuring structural uniformity, particularly in the consistent accumulation of deformations across the cross section of parts, to enhance their durability and operational lifespan.