IATF 16949:2016 and ISO 9001:2015

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Forged Automotive Components

Trusted Forging Component Manufacturer & Supplier

IATF 16949:2016-certified metal forgers for automotive components   

Sendura Forge is a forging component manufacturer, supplier, and exporter based in Rajkot, Gujarat. At our forges, we produce a range of machine parts, including forged automotive components, for domestic and international businesses. We deliver tight tolerances, superior builds, and precise dimensions that meet IATF expectations. Our production methodology is built on the ‘Plan-Do-Check-Act’ framework, ensuring our deliverables remain compliant with industry standards. 

When partnering with us, tier-1 suppliers and OEMs avail the benefits of strategic sourcing, scalable production, and a robust testing-cum-traceability system. The benefits: insurance against supply chain shocks, negligible return outwards, and lower total cost of ownership. They also benefit from logistics, one-to-one, and technical advisory support. 

Attention to detail and compliance awareness around design, application, and export have enabled us to emerge as a trusted forging component supplier to DANA, Mahindra, TAFE, ESCORTS, and more. 

Learn how our technical pedigree, infrastructure, and engineering teams can successfully conclude your project.

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Our Portfolio of Forged Automotive Components

We forge all major automotive components. This includes engine, transmission, gear, and exhaust systems. Here are some of the more popular forged automotive components to come out of our shop floor. 

Helical Gear and Shaft

Close-die hot-forged helical gear and shaft that enables smooth transfer of power at higher torques. With the aid of 4140, 8620, and similar case-hardened steels, this gear and shaft assembly can take a great deal of axial and radial loading. It also significantly reduces noise, vibration, and hardness during operations. A significant part of the transmission system, the helical gear and shaft we produce exhibit an excellent operational lifespan. 

Gear Blanks

The foundational geometry for gears, we manufacture gear blanks using the closed-die process. The gear blanks that we produce have superior toughness, nice tight tolerances, and are prepared for the next step of gear-tooth slicing; we forge these using the strongest of alloy steels, such as 8620 and 4140, providing maximum performance and resistance to fatigue. 

Balancing Shaft

Balancing shafts spin at nearly twice the crankshaft’s speed to nullify system harmonics and provide a better cabin experience. We manufacture balancing shafts using 1045 and 4140 steel, which results in superior fatigue and wear resistance under continuous high-rpm bending stress. 

Cross Shaft

These simple-looking forged automotive components play a complex role, transmitting continuous torque between non-aligned rotating shafts. Given the demanding workload, we close-die forge them from case-hardened alloys and 8620 steel for superior surface hardness and core toughness.

Machine Shaft

The machine shaft transfers rotational energy among various automotive components. During operations, this foundational component handles a high degree of shear, bending, and torsional stress. We manufacture this forged automotive component using 1045, 4140, and other high-tensile steel for extended operational life and lower maintenance requirements.

Ring Gear Carrier

A heavy-duty structural housing for differential and internal spider gears, ring gear carriers operate under immense torsional load. To ensure longevity and sustained performance across operational cycles, we hot forge them using 8620 and 4140 steel. 

Technical Overview of Our Forged Components

Details pertaining to the above-mentioned forged components. 

Forging method Closed-die
Materials Stainless steel, low-carbon steel
Heat treatment Quenching, tempering, normalizing
Weight-range Up to 30 kg (individual pieces)
Surface treatment Chrome-plating, electroplating, shot-blasting 
Tolerance CT6–7
Surface finish ~3.2–6.3 µm Ra

What Makes Us a Reliable Forging Component Supplier

We understand the procurement and engineering anxieties that accompany every project. This understanding informs everything—from product development to testing. Here’s a short primer on the same.

  • Product Development: (IATF compliant product development). (APQP), (PFMEA), (MSA), (CP) are integrated together to provide a complete PPAP. Ours is a Kaizen-oriented system and engages the top leadership as well as the shop floor operators in the development process. 
  • Sourcing: A comprehensive network of raw material suppliers for obtaining high-quality raw materials. We work with suppliers who provide mill testing certificates for every delivery and run internal checks ourselves for verification. Plus, we maintain a buffer stock of raw materials to mitigate shortfalls during times of market duress. 
  • Data-driven Production: We create in-house digital designs and run simulations to iron out major issues before production. This is entirely possible because we rely on advanced CAD/CAM systems and take a data-driven approach to production planning. 
  • Robust Infrastructure: We forge and produce using a range of drop hammers, trimming presses, coin presses, and three-axis milling centers to ensure production lines don’t grind to a halt because of technical failures. 
  • Testing and Traceability: These two processes are integrated into our production system. Traceability begins right from the first forging, while testing happens after every key manufacturing stage to ensure dimensional compliance. Post-production, components undergo a range of inspections, including geometric checks (CMM) and magnetic particle testing. 
  • Trained Workforce: Our operators and technicians do not operate in silos but work in tandem as integrated units. Shop floor workers work with the latest designs and specifications and are trained to understand the impact of each manufacturing step in the overall compliance process. Similarly, our die-creation and testing technicians work together, forming a feedback loop that helps achieve CAD-to-part parity. 
  • Operational Tenure: Sendura Forge has been producing forged automotive components and other forged components for more than 25 years. Our years of operation have equipped us with on-the-ground challenges, unique to individual industries, and how to best navigate them.  Attention to detail along with awareness of any and all changes in the requirements for design, manufacturing materials, and compliance has allowed us to distinguish ourselves from our competitors as a reliable source for forged components. We currently ship forged parts globally to customers in the U.S.A., U.K., France, Germany, Italy, Saudi Arabia, U.A.E, Japan, South Korea, and Australia.

Discuss Your Forging Component Requirements

Our team of experts can alleviate your sourcing challenges. We produce a range of components for automotive, defence, and earthmoving businesses. Bring your designs and specifications and avail 1-1 support and payment terms that work for you. 

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FAQs

1. What requirements are necessary for an RFQ at Sendura?

For an RFQ, share your design, material specifications, volume requirements, batch runs, program lifetime, heat and surface treatment requirements, submission levels, incoterms, and packaging specs with our team.  

2. Does Sendura Forge manufacture custom designs?

Yes, we routinely manufacture custom designs provided they can be forged. We have the infrastructure, access to raw materials, a modern die shop, and an experienced workforce to see the production of custom parts from concept to finished component. 

3. What is the lead time for production?

Lead times for standard designs are between 25 and 40 days, depending on volume requirements. For custom forgings,  it’s subject to design complexity and material choice. Lead time will also vary based on delivery destination. Contact us for further details.

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