Payment & Shipping Terms:
|Material:||Alloy Steel 4140 4340 8620||Process:||Drop Forging Process|
|Machining:||CNC Machining||Surface:||Natural Color|
|Packing:||Plywood Crate||Heat Treatment:||Quench & Temper|
forged steel components,
forged metal parts
OEM Forging Products For Auto Cars 4140 4340 Alloy Steel Forging Parts Supplier
Product Description and Process
OEM Forging Products For Auto Cars 4140 4340 Alloy Steel Forging Parts Supplier
Production process: metal hot forging process
Machining process: CNC machine, machining center, lathe, mill machine, drill machine, etc.
Surface treatment process: paint coating, electrophoretic coating, electrogalvanizing coating, black oxide coating, powder coating, etc.
Product Material and Uses
Normally produce with low carbon steel, medium carbon steel, low alloy steel, such as 1020 steel, 1035 steel, 1045 steel, 16Mn, Q235, Q345, A105, 20MnMo, 35Crmo, 42CrMo, etc.
The steel forging products are widely used for auto-car parts, truck parts, train parts, vehicle components, construction machinery components, other machinery components, etc.
Forging Advantages and disadvantages
Forging can produce a piece that is stronger than an equivalent cast or machined part. As the metal is shaped during the forging process, its internal grain texture deforms to follow the general shape of the part. As a result, the texture variation is continuous throughout the part, giving rise to a piece with improved strength characteristics. Additionally, forgings can target a lower total cost when compared to a casting or fabrication. Considering all the costs that are involved in a product’s lifecycle from procurement to lead time to rework, and factoring in the costs of scrap, downtime and further quality issues, the long-term benefits of forgings can outweigh the short-term cost-savings that castings or fabrications might offer.
Some metals may be forged cold, but iron and steel are almost always hot forged. Hot forging prevents the work hardening that would result from cold forging, which would increase the difficulty of performing secondary machining operations on the piece. Also, while work hardening may be desirable in some circumstances, other methods of hardening the piece, such as heat treating, are generally more economical and more controllable. Alloys that are amenable to precipitation hardening, such as most aluminum alloys and titanium, can be hot forged, followed by hardening.
Production forging involves significant capital expenditure for machinery, tooling, facilities and personnel. In the case of hot forging, a high-temperature furnace (sometimes referred to as the forge) is required to heat ingots or billets. Owing to the size of the massive forging hammers and presses and the parts they can produce, as well as the dangers inherent in working with hot metal, a special building is frequently required to house the operation. In the case of drop forging operations, provisions must be made to absorb the shock and vibration generated by the hammer. Most forging operations use metal-forming dies, which must be precisely machined and carefully heat-treated to correctly shape the workpiece, as well as to withstand the tremendous forces involved.
There are many different kinds of forging processes available; however, they can be grouped into three main classes:
Drawn out: length increases, cross-section decreases
Upset: length decreases, cross-section increases
Squeezed in closed compression dies: produces multidirectional flow
Common forging processes include: roll forging, swaging, cogging, open-die forging, impression-die forging, press forging, automatic hot forging and upsetting.
Automatic hot forging
The automatic hot forging process involves feeding mill-length steel bars (typically 7 m (23 ft) long) into one end of the machine at room temperature and hot forged products emerge from the other end. This all occurs rapidly; small parts can be made at a rate of 180 parts per minute (ppm) and larger can be made at a rate of 90 ppm. The parts can be solid or hollow, round or symmetrical, up to 6 kg (13 lb), and up to 18 cm (7.1 in) in diameter. The main advantages to this process are its high output rate and ability to accept low-cost materials. Little labor is required to operate the machinery.
There is no flash produced so material savings are between 20 and 30% over conventional forging. The final product is a consistent 1,050 °C (1,920 °F) so air cooling will result in a part that is still easily machinable (the advantage being the lack of annealing required after forging). Tolerances are usually ±0.3 mm (0.012 in), surfaces are clean, and draft angles are 0.5 to 1°. Tool life is nearly double that of conventional forging because contact times are on the order of 0.06-second. The downside is that this process is only feasible on smaller symmetric parts and cost; the initial investment can be over $10 million, so large quantities are required to justify this process.
The process starts by heating the bar to 1,200 to 1,300 °C (2,190 to 2,370 °F) in less than 60 seconds using high-power induction coils. It is then descaled with rollers, sheared into blanks, and transferred through several successive forming stages, during which it is upset, preformed, final forged, and pierced (if necessary). This process can also be coupled with high-speed cold-forming operations. Generally, the cold forming operation will do the finishing stage so that the advantages of cold-working can be obtained, while maintaining the high speed of automatic hot forging.
Examples of parts made by this process are: wheel hub unit bearings, transmission gears, tapered roller bearing races, stainless steel coupling flanges, and neck rings for LP gas cylinders. Manual transmission gears are an example of automatic hot forging used in conjunction with cold working.
Roll forging is a process where round or flat bar stock is reduced in thickness and increased in length. Roll forging is performed using two cylindrical or semi-cylindrical rolls, each containing one or more shaped grooves. A heated bar is inserted into the rolls and when it hits a spot the rolls rotate and the bar is progressively shaped as it is rolled through the machine. The piece is then transferred to the next set of grooves or turned around and reinserted into the same grooves. This continues until the desired shape and size is achieved. The advantage of this process is there is no flash and it imparts a favorable grain structure into the workpiece.
Examples of products produced using this method include axles, tapered levers and leaf springs.
Net-shape and near-net-shape forging
This process is also known as precision forging. It was developed to minimize cost and waste associated with post-forging operations. Therefore, the final product from a precision forging needs little or no final machining. Cost savings are gained from the use of less material, and thus less scrap, the overall decrease in energy used, and the reduction or elimination of machining. Precision forging also requires less of a draft, 1° to 0°. The downside of this process is its cost, therefore it is only implemented if significant cost reduction can be achieved.
WHAT DO WE OFFER?
We are the forging parts solutions provider. The types of forgings we produce can range from a fraction of 0.5 pound up to 350 lbs. Our capabilities in materials include multiple grades and types of metals, depending on the end use. Carbon, alloy and stainless steels, as well as aluminum, brass and titanium can all be forged. We also offer a range of additional services, allowing us to stay competitive and directly supply finished product to our customers.
WHY Choose US?
We are a comprehensive forging solutions provider committed to excellence in everything we do. In addition, we are ISO 9001 certified. Our engineering team utilizes various computer modeling techniques and the latest technological capabilities, as well as extensive physical testing. We offer our partners a dependable link in their supply chain by constantly focusing on quality, short lead times and competitive pricing. Each forging, no matter how complex, is also backed by our ongoing customer service and expert engineering.
Contact Person: Mr. James Wang
Tel: +86 13213152686