Forging Services

Forging is a manufacturing process involving the shaping of metal using localized compressive forces of a hammer or a die (Open Die & Closed Die). Forgings are broadly classified based on the temperature at which it is formed as Cold, Warm & Hot forging. For the latter two, the material is heated up to a certain range of temperature. Depending on the type of die used, the Closed die shall provide better dimensional control and strength. To meet the increasing demand for customized part requirements many new forging technologies have evolved such:

• Ring Rolling – It is used to produce seamless rings varying in size from a few inches in diameter and weighing less than a pound to over 20 feet in diameter
• Radial Forging – Part is forged with the help of four dies arranged in one plane acting simultaneously in radial direction
• Orbital Forging – Part is held in a die cavity and forged by compressive forces of the upper die revolving on an inclined axis
• Upset Forging - It involves locally heating a metal bar and then, while holding it firmly with special tooling, applying pressure to the end of the bar in the direction of its axis to deform it
• Extrusion Forging – It is done by deforming metal and flowing it into a chamber, and then compressing the metal while it is inside the chamber at extreme temperatures

Capabilities

• Prototype to high volume production of up to thousands of parts per year based on part configuration
• Forging of parts from few Kgs up to more than 10 Tonnes
• Manufacturing of wide variety of material grades such as Carbon steel, Alloy steel, Tool steel and Superalloys
• Gas and Electric operated Heat Treatment furnaces for heating of pre-form as well post heat treatment such as Annealing, Normalizing, Hardening, Tempering etc.
• Up to 4000 Tonnes fully automatic Hydraulic press
• Mobile charging machines and forging manipulators
• Flexibility of end-to-end machining of small to large sized parts
• Tolerance of close die forged parts up to ± 0.25mm based on the characteristics of the part and machined tolerance of up to ± 0.02mm
• CMM inspection for part validation and approval of machined parts
• In-house lab tests carried out for raw material verification at production site, certified to NABL standards
• Complete NDT testing of parts for defect analysis as per international standards
• Manufacturing facility certified to IATF 16949 and AS 9100 Rev.D Quality Management System
• Globally approved system, client, and product certifications

Application and Benefits

• A variety of forged parts are used in the Aerospace and Defence industry specifically made from Aluminum alloys, Alloy steels, Superalloys, and composites. Few of them are shafts, turbine blades, torpedo’s, canisters, domes, missile launchers etc.
• Common applications in Oil & Gas, Valve and Power Generation sector include flanges such as weld-neck, rolled, lap-joint flange; rings and connectors such as seat ring, labyrinth ring, seal ring retainer ring, body adapter etc.
• Other general engineering applications include shafts, gears, pistons and cylinders, transmission parts etc.
• Forgings are used particularly in critical applications where the parts are subjected to extreme operating environment. Few of their benefits over castings are listed below:

1. Higher strength, toughness, and structural integrity
2. Longer service life
3. Higher design stresses
4. Increased safety due to ductility
5. Greater strength to weigh ratio
6. No porosity