Various types of Forgings

Type of Forgings

Mettalics Forge cast has a long standing reputation in forging industry with forging process like Open & Close die forgings, Press forgings, Upsets forgings, Seamless rolled ring forgings & Impression die forging using pneumatic hammers, equipped with necessary infrastructure such as house die shop and associated facilities like Heat Treatment shop, Chemical & Physical Laboratories, the company has been in a position to meet forging requirements of number reputable OEMs across the country. Our Clients list includes OEMs of Stationary Diesel Engines, Pressure Vessels, Light & medium Transport Vehicles, Earthmoving Equipment, Industrial Conveyors, Railways, Automobile etc. Our world class infrastructure compiled with the latest CAD/CAM, CNC, MRP and automated manufacturing technologies enable us to provide you the best quality forged materials at the most competitive prices. Our research and development cell is always on its toes to provide you the innovative trends as far as forging industry and metallurgical developments are concerned.

We source our raw materials from approved steel plants such as RINL, ISSAL, MUSCO, SAIL and TISCO etc. All incoming Raw materials are checked thoroughly in our Chemical Lab, by qualified metallurgists. Our qualified & experienced team of professionals achieved quality-working conditions at all levels (Design, Tool room management & execution) of operations.

We are manufacturing various types of forging components like Connecting Rods, Crankshafts, Camshafts, Gears, Gear Blanks, Pinion, Crown Wheel, Gear Shifter Forks, Torque Converter Cover, Universal joint components, Bucket tooth and many more intricate components with fully CNC Machined and finished parts.

Forging is the process by which metal is heated and is shaped by plastic deformation by suitably applying compressive force. Usually the compressive force is in the form of hammer blows using a power hammer or a press.

Forging refines the grain structure and improves physical properties of the metal.Forgings are consistent from piece to piece, without any of the porosity, voids, inclusions and other defects. Thus, finishing operations such as machining do not expose voids, because there aren't any. Also coating operations such as plating or painting are straightforward due to a good surface, which needs very little preparation.

Common Forging Processes

Open Die Forgings / Hand Forgings:

Open die forgings or hand forgings are made with repeated blows in an open die, where the operator manipulates the work piece in the die. The finished product is a rough approximation of the die. This is what a traditional blacksmith does, and is an old manufacturing process. We are backed up with Forging Hammers from 1 Ton to 5 Ton Capacity and Presses of 4400 T and 1600 T.

Impression Die Forgings / Precision Forgings:

Impression die forgings and precision forgings are further refinements of the blocker forgings. The finished part more closely resembles the die impression. We have pneumatic hammers for doing the Impression Die Forgings.

Press Forgings:

Press forging use a slow squeezing action of a press, to transfer a great amount of compressive force to the work piece. Unlike an open-die forging where multiple blows transfer the compressive energy to the outside of the product, press forging transfers the force uniformly to the bulk of the material. This results in uniform material properties and is necessary for large weight forgings. Parts made with this process can be quite large as much as 125 kg (260 lb) and 3m (10 feet) long.

Upset Forgings:

Upset forging increases cross-section by compressing the length, this is used in making heads on bolts and fasteners, valves and other similar parts. We are backed up with Forging Up setters from 1.5 Inch to 15 Inch Dia.

Seamless Rolled Rings Forgings :

Seamless rolled ring forging is typically performed by punching a hole in a thick, round piece of metal (creating a donut shape), and then rolling the donut into a thin ring. We have 4 Ring Rolling Mills equipped with Schuler presses with capacity to produce rings upto 500mm (20 inch) Outer Dia and upto 25 KG (55 lbs) in weight. We can also make Contoured Rings so as to reduce the machining allowances to a minimum and make them very similar to the final shapes.

Swaging:

Swaging - a tube or rod is forced inside a die nd the diameter is reduced as the cylindrical object is fed. The die hammers the diameter and causes the metal to flow inward causing the outer diameter of the tube or the rod to take the shape of the die.

Aluminum Forgings:

Aluminum drop forged pieces will always offer the most economic solution when, in addition to light weight, such factors as strength, appearance and recycling potential are also important. We specialize in aluminum drop forged pieces. We can employ any aluminum allow (ex - HE12, HE15, HE30, 6061, 6063 and others) according to the demands of the individual assignment. We carry out production in small, medium and large batch quantities with an individual weight of up to 15 kilograms. We do closed die forgings using the most modern Friction Screw Presses and Drop Hammers.

Automotive:

Crankshafts, Camshafts, Connecting Rods, Front Hub, Differential Case and Cover, Rocker Arms, Transmission parts, Steering Arms and Knuckles.

Material Handling / Construction / Earth Moving:

Track Links, Gears, Rollers, Idlers, Crane Wheels, Trunions, Piston eyes, Couplings.

Mining:

Cylinders, Front and Back Heads for Pneumatic Rock, Breaking tools, Leg and Cone forgings for drill bits, Rack Segment.

Oil and Gas:

Bonnets, Valve Bodies, Gates, Flanges, T's, Elbows, Xmas Tree Caps, Discs for Valves, Forged Fittings.

Heavy Engineering Industries:

SUGAR, CEMENT, STEEL, TEXTILES, MINING, RAILWAYS, POWER, CONSTRUCTION, MARINE, Rollers, Pinions, Shafts, Spindles, Piston Rods, Gear Blanks.