Forging production

Traditional custom production of steel forgings

At our company, we specialize in manufacturing closed-die forgings using carbon and alloy steels, as well as stainless steels. Our technological equipment enable us to produce components in both vertical and horizontal orientations, We forge parts with complex geometries and kinked dividing planes.

We operate five forging lines, each equipped with an electric induction furnace to heat steel to the appropriate forging temperature. Each workshop also features one or two forging presses, along with an additional press for trimming excess material - flash.

Technical parameters of the forgings

• Forging weight from 0.05 kg to approx. 4.00 kg depending on the shape, complexity and material quality.
• Max. length or height 350 mm.
• Formed area up to a maximum diameter of 175 mm, or other shapes of corresponding sizes.

Used materials:

• Carbon steels
  • S235JR, S355J2, C35E, C45E, C55E, C60 and others.
• Low and high alloy steels
  • 37MnSi, 38MnVS6, 16/20MnCrS5, 42CrMo4, 50CrMo4, 30Cr2V, 38Cr2V, 20NiCrMo2-2, 15NiCr13 and others.
• Stainless steels
  • 1.4021, 1.4462, 1.4571 and others.

What types of forgings do we produce?

• Camshafts, cranks or eccentric shafts.
• Cranks, cylinders, connecting rods, weights, weight carriers.
• Clutch hubs and disc hubs.
• Nuts and bolts.
• Brake pins, clutches, armrests.
• Clips, flaps, sleeves, levers.
• Elbows, washers, clamps and various bodies.
• Hooks and shackles.
• And others according to customer requirements.

How is the technological preparation of production carried out?

We utilize the advanced CAD/CAM system SolidWorks for our design and technological preparation processes. This software allows designing forgings and forging tools, as well as cutting tools. Additionally, it enables us to generate programs for CNC machining, ensuring precision and efficiency in our production operations.

How are forgings produced?

• We divide steel bars on three automatic saws.
• We heat the cut semi-finished products to the forging temperature solely in induction heaters, the heating is regulated and controlled by a system of pyrometers.
• We shape forgings gradually on spindle or crank presses, we cut off the excess material of the forgings on eccentric and crank presses.
• From the forging temperature, we cool down the forgings in air or controlled in a cooling tunnel.
• We perform normalizing annealing of forgings in a continuous furnace, soft annealing in a chamber furnace.
• Quenching and tempering of forgings is provided in cooperation.
• Scale removal from forgings is carried out in a drum blaster
• The surface of the forgings is inspected using the magnetic particle method.
• We perform cold calibration of the forgings using a spindle press
• Product quality is guaranteed by measuring with 3D measuring equipment and classic measuring gauges

What machines do we have at our disposal?

• ExactCut automatic circular saws, Bomar band saw.
  
• Roboterm induction heaters with a power of 250 to 400 kW - KSO 250, KSO 400.
• Spindle forging presses for forging with a forming force of 250 tons to 630 tons - LFJ 250, LVR 400, LVR 630.
• Crank forging presses with a forming force of 630 tons to 1600 tons - Šmeral LKM 630, LZK 1600, LMZ 1600.
  
• Forging workshop with LMZ 1600
• Trimming presses LU 100, LE 160, LKO 315.
• Continuous normalizing furnace, chamber furnace.
• Drum blasting machine Wheelabrator MB 200G.

Standard start of custom forging production

• Design and approval of forging drawings.
• Design and technological preparation of production.
• Simulation of the forging process
• Production of forging and trimming tools.
• Production of forging samples including the inspection report of the first samples.
• Approval of samples by the customer.
• Serial production.