Our assurance towards accurate geometry begins with simulations and concludes with a series of visual and mechanical inspections. Here’s a primer on how this system works.
Pre-production Stage
Die Creation
As a precision forging company, we understand that producing near-net finishes that require few secondary operations begins with dimensionally sound tooling. Our technicians use modern CAD/CAM software to simulate grain flow, eliminate possible defects, and optimize the die design before billets enter the induction furnace. Once finalised, the design is carefully machined using 3-axis VMCs in our machine shop under close oversight.
Billet Production
We make our billets from quality raw materials. The materials are themselves checked for quality control, and on passing inspection, move to the cutting shop. Here, workers cut the rods into pre-determined sizes using a band saw. Constant dimensions make it easy to stack the materials into billets and facilitate even heating in the furnace.
Thermal Control
Precision forging depends on achieving the right furnace temperature. Underheating can cause the billet to not achieve enough plasticity, while overheating can cause the metal to break when pressing or folding. We achieve and maintain temperature accuracy across our induction furnaces using software automation. This prevents scale formation, ensures optimal plasticity, and enables automatic accept/reject.
Production Stage
Forging
We have paired our shop drop hammers with stroke-control techniques so that any time the hammer hits a stock material, it has the same amount of energy, providing consistency between product lines. In addition to the standard closed-die forging processes that provide repeatable dimensional precision, each drop hammer is interfaced to a CAD system, allowing engineers to use current design data.
Coining
While the component is still warm, we introduce it into a coin press. This creates smooth surfaces, but it also establishes traceability. We introduce physical markers at this stage, such that any deformity can be tracked to a specific stage and then rectified.
Heat-treatment
The forged components undergo heat treatment to improve material properties such as hardness. Our finely-tuned system ensures we are able to achieve consistent Brinell and Rockwell hardness specifications across high-volume runs.
Post-production Stage
Machining
We feed our CAD/CAM data into our HMCs and VMCs to ensure accurate milling. The milling centers remove the right amount of material while ensuring repeatable accuracy for corners, curves, grooves, and other complex shapes.
Inspections
Precision assurance is incomplete without testing. Every component undergoes geometric inspection on coordinate measuring machines to ensure CAD-to-part mirroring. Furthermore, we carry out spectrometric testing, microscopic inspections, and magnetic particle testing to ensure functional and compliance-driven precision.
Traceability
Post QC-Pass, physical stamps are vetted against digital passports. This guarantees complete heat-to-heat and metallurgical traceability throughout the component’s operational lifespan and helps us become a better precision forging company.
