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FORGINGS

CALMET offers a wide range of forgings services to meet the diverse needs of its clients. With state-of-the-art facilities and a team of skilled professionals, we ensure the highest quality standards in every forging project we undertake, whether custom designs or mass production.

Best suited Forging processes are employed to meet your exacting requirements from carbon and alloy steels to stainless and exotic material grades for full spectrum of applications.

Open Die Forgings can be produced from a few pounds to a few tons. Closed Die Forgings range from a few ounces to as much as 50 lbs. Rolled Rings components up to 100″ in diameter.

Processes:

Hot Forging

In hot forging, the metal is heated above its recrystallization temperature, making it easier to deform. The heated metal is then shaped using mechanical processes like hammering or pressing. Hot forging requires less force, allows for faster production rates, and produces components with improved material properties and reduced residual stresses. Commonly used for large and complex parts in industries like automotive, aerospace, and heavy machinery.

Cold Forging

In cold forging, the metal is deformed at room temperature or slightly above. This process is more precise and produces parts with tighter tolerances and higher surface finish. Cold forging results in stronger parts with excellent surface finish, reduced material waste, and increased production efficiency. Ideal for producing small to medium-sized components requiring high accuracy and surface quality, such as fasteners, gears, and connectors.

Metal Forging Processes

  • Open-Die Forging: Metal is placed between multiple dies not enclosing the metal entirely, allowing it to be deformed by hammering or pressing. It is used for large parts and involves repeated strikes.

  • Closed-Die (Impression-Die) Forging: Metal is placed between two dies that contain a shaped cavity. When the dies are brought together, the metal flows and fills the cavity, creating more complex shapes. The process produces near-net shapes, requiring minimal machining.

  • Drop Forging: Involves dropping a hammer onto the metal piece, which is positioned between two dies. Depending on the final requirement, it is applied open-die or closed-die.

  • Press Forging: Uses a slow, continuous pressure or force instead of impact force to shape the metal. This is done with open or closed dies.

  • Roll Forging: The metal is passed through two cylindrical or semi-cylindrical rolls with grooves that form the desired shape.

  • Swaging: Involves rotating dies that hammer the metal into the desired shape as it is fed through the machine. It is often used for reducing the diameter of rods or tubes.

  • Upset Forging: Involves increasing the diameter of the metal by compressing its length. This is commonly used to form bolt heads, valves, and other components.

  • Isothermal Forging: The metal and the die are heated to the same temperature, allowing the metal to flow more easily and producing more precise and consistent parts.

Each of these processes has its own advantages and is chosen based on the desired properties of the final product, the type of metal used, and the specific application.

Forgings:

Alloy CNC Components

Auto Components

Bush Parts

Fitting Parts

CNC Parts

Turned Components

Machinary Parts

Steel Flange

Farm Equipment Pulley

Pump Parts

Sleeve Coupling

Valve Parts

Forging Material Properties

We work with a variety of material grades to meet the diverse needs of our clients, depending on the application, desired mechanical properties, and environmental conditions. Here are some common forging materials we work with:

Grades Properties
Alloy Steel Includes number of steels whose qualities have been adjusted or improved by alloying the steel with extra metals such as silicon, manganese, or nickel. These enhance properties like corrosion resistance, malleability, or thermal/electrical conductivity. Forged alloy steel parts have high wear resistance and strength.
Carbon Steel Contains more carbon than ordinary steel, which adds to greater strength. Therefore, the metal performs well in high-temperature and high-pressure applications.
Stainless Steel Stainless steel is extremely corrosion resistant, heat resistant, strong, and long-lasting. When the metal is forged, all of these qualities are enhanced even further.
Aluminium The metal has a superior strength-to-weight ratio due to its low density and is stable at lower temperatures as well. Grades 6061 and 7075 aluminum alloys are common. Resistant to corrosion and withstands harsh situations such as those found in aerospace applications.
Micro-alloy Steel Alloys with additives of Vanadium, Titanium, or Nobium additions. As it cools, micro-alloy steel acquires exceptional toughness and often does not require post-heat treatment to enhance mechanical characteristics.
Copper Alloys Grade C11000 (Electrolytic Tough Pitch Copper) has excellent thermal and electrical properties, used in electrical applications and heat exchangers. Grade C95400 (Aluminium Bronze) has high strength, corrosion resistance, and wear resistance, suitable for marine and industrial applications.

Each material grade offers unique properties and advantages, allowing us to tailor our forgings to meet the specific requirements. Whether you need high strength, corrosion resistance, or heat resistance, we have the expertise to recommend the right material grade for your forging needs.

Forgings Applications by Material

Each material offers unique properties that cater to specific application requirements in diverse industries.

Grades Applications
Alloy Steel Alloy steel forged parts find applications in aerospace components, oil and gas equipment, power generation, and heavy machinery. The addition of alloying elements enhances the strength, wear resistance, and corrosion resistance of these components, making them suitable for demanding environments.
Carbon Steel Carbon steel forged components are commonly used in automotive parts, machinery components, hand tools, and structural fittings. Their strength, toughness, and affordability make them ideal for a wide range of applications where high strength and durability are required.
Stainless Steel Stainless steel forged components are utilized in industries such as food processing, pharmaceuticals, chemical processing, and marine applications. The corrosion resistance, hygiene, and aesthetic appeal of stainless steel make it well-suited for environments that require cleanliness and durability.
Aluminum Aluminum forged parts are used in aerospace structures, automotive components, electronic enclosures, and consumer products. The lightweight, corrosion resistance, and thermal conductivity of aluminum make it a preferred choice for applications where weight reduction and thermal management are critical.
Titanium Titanium forged components are utilized in aerospace, medical implants, marine applications, and high-performance sports equipment. The high strength-to-weight ratio, corrosion resistance, and biocompatibility of titanium make it an ideal material for applications where lightweight and durability are essential.
Brass and Copper Brass and copper forged parts are commonly used in plumbing fittings, electrical contacts, decorative hardware, and musical instruments. The malleability, conductivity, and corrosion resistance of these materials make them suitable for applications that require both functionality and aesthetics.
Nickel-based Alloys Nickel-based alloy forged components are prevalent in chemical processing, petrochemical industries, gas turbines, and nuclear power plants. The high-temperature strength, corrosion resistance, and creep resistance of nickel-based alloys make them ideal for applications in extreme environments.

By selecting the appropriate material for forging based on the desired characteristics and operating conditions, we can ensure the optimal performance and longevity of forged components in various applications.

3 Stage Quality Control Check Process

Incoming Inspection:

The incoming inspection stage involves evaluating the raw materials that will be used for forging to ensure they meet the required specifications and quality standards.

Process

  • Dimensional Check: Verify the dimensions of the raw material against the design specifications to ensure they are within tolerance.
  • Material Analysis: Conduct material testing to confirm the composition and properties of the raw material meet the required standards.
  • Surface Inspection: Examine the surface of the material for defects, such as cracks, pits, or surface contamination.

Action

  • Acceptance: If the material passes all tests and meets the quality criteria, it is approved for use in the forging process.
  • Rejection: Any material that fails to meet the required standards is rejected to prevent quality issues during forging.

In-Process Inspection:

The in-process inspection stage focuses on monitoring and controlling the forging process to ensure the quality of parts being produced at different stages.

Process

  • Dimensional Check: Measure the dimensions of forged parts periodically to ensure they align with the design requirements.
  • Visual Inspection: Visual inspection of the parts for surface defects, cracks, or imperfections during forging.
  • Surface Inspection: Monitor and maintain the required temperature and pressure levels during the forging process to prevent defects.

Action

  • Adjustments: If any deviations or defects are detected, necessary adjustments can be made to the forging process to ensure the quality of the parts.
  • Feedback: Provide feedback to operators and supervisors to address any issues that arise during forging promptly.

Final Inspection:

The final inspection stage is conducted once the forging process is complete to verify that the finished parts meet the required quality standards before they are released for further processing or shipment.

Process

  • Dimensional and Visual Inspection: Conduct a comprehensive inspection of the final forged parts to check for dimensional accuracy, surface finish, and overall quality.
  • Material Properties Testing: Perform material testing on finished parts to ensure they possess the required mechanical properties and meet material specifications.
  • Non-Destructive Testing: Utilize non-destructive testing methods like ultrasonic testing or magnetic particle inspection to detect internal defects or flaws.

Action

  • Acceptance: If the forged parts pass all quality checks and meet the defined criteria, they are approved for the next stage of processing or shipment.
  • Rejection: Any parts that do not meet the required quality standards are rejected to prevent the use of defective components in the final products.

Case Study:

Forged Metal Connecting Rod for Automotive Engines

Introduction

This was done for the production of a forged metal connecting rod used in automotive engines. Connecting rods are essential components that connect the piston to the crankshaft, transferring motion and force. The focus is on material selection, the forging process, quality control, and economic aspects of the production.

Material Selection

The chosen material for the connecting rod is 4340 alloy steel, for a good balance of strength, toughness, and fatigue resistance with Tensile Strength 745 MPa, Yield Strength 470 MPa, Elongation 12% and Hardness: 217 HB

Design and Simulation

  • CAD Modelling: A detailed CAD model of the connecting rod was created.
  • Finite Element Analysis (FEA): The model underwent FEA to predict stress distribution and deformation during forging.

Material Preparation

Billets were cut to the required size and then heated in a furnace to approximately 1200°C to make the metal malleable.

Forging Operations

Initially, heated billets were placed in a hydraulic press with a capacity of 4000 tons to create the rough shape of the connecting rod. Then rough shape was refined with subsequent press operations to ensure accurate dimensions and proper grain flow. Final touches were made to achieve near-net shape, minimizing the need for extensive machining.

Heat Treatment

Quenching and Tempering: The forged connecting rods were quenched in oil and tempered to achieve the desired mechanical properties.

Machining

  • CNC Machining: The forged components were machined to precise tolerances, ensuring smooth surfaces and correct dimensions.
  • Grinding and Polishing: Critical surfaces were ground and polished to achieve the necessary finish and dimensional accuracy.

Quality Control

  • Dimensional Inspection: CMM Used to verify the dimensions of the connecting rod against design specifications.
  • Non-Destructive Testing (NDT): Ultrasonic Testing: To ensure there were no internal defects like cracks or inclusions.
  • Magnetic Particle Testing: MPT to identify surface and near-surface defects.
  • Microstructural Analysis: Metallography for examining the grain structure and verifying uniformity and proper grain flow.
  • Mechanical Testing: For Tensile Test and Hardness Test.

Economic Considerations

  • Cost of Material: 4340 alloy steel is relatively expensive but was justifiable due to its superior properties.
  • Tooling Costs: High initial investment in dies and molds, but cost-effective for large production runs.
  • Production Efficiency: Forging is chosen over casting and machining due to its ability to produce strong, durable components with minimal waste.

Environmental Impact

  • Energy Consumption: Significant energy is required for heating and forging processes.
  • Waste Management: Efforts are made to minimize waste through efficient material utilization and recycling of scrap material.
  • Emissions: Controlled emissions during the heating process to comply with environmental regulations.

Conclusion

The production of a forged connecting rod involves careful material selection, precise forging operations, and stringent quality control measures. 4340 alloy steel is ideal for this application due to its high strength and toughness. While the initial costs are high, the forging process ensures high-quality components with superior mechanical properties, making it a cost-effective choice for mass production. Additionally, attention to environmental impact ensures sustainable production practices.
This case study provides a detailed overview of the production process for a critical automotive component. If you need more details or specific focus on any section, feel free to ask!

Why Calmet?

To maintain a competitive advantage in the steel casting industry, Calmet always evaluates its unique strengths and value proposition. Here are some factors to consider while analyzing the competitive advantage that Calmet offers:

1. Quality and Expertise

  • Expertise and experience in specialized processes provide an edge over competitors.
  • Certification of quality standards, adherence to industry-specific regulations, and continuous improvement initiatives have immensely helped Calmet and its customers.

2. Technological Capabilities

  • Cutting-edge technology and equipment that Calmet employs significantly enhance the efficiency and quality of the manufacturing process.
  • Investment in advanced machinery, automation, and digital tools can lead to cost savings, faster production cycles, and better forging outcomes.
  • Strong R&D capabilities to develop new alloys and casting methods can differentiate a firm from its competitors and attract customers seeking innovative solutions.

3. Supply Chain Management

  • Efficient supply chain management, including sourcing raw materials, logistics, and inventory control, can optimize costs and lead times.
  • Building reliable relationships with suppliers and ensuring a steady supply of high-quality raw materials can give the firm an advantage in meeting customer demands promptly.
  • Implementing just-in-time manufacturing practices and adopting lean principles can enhance competitiveness by minimizing waste and maximizing efficiency.

4. Customer Relationships

  • Developing strong customer relationships and providing exceptional customer service is a way of life at Calmet. Every employee is dedicated to this philosophy.
  • Understanding customer requirements, providing technical support, and offering customized solutions have helped us stand ahead of competitors.
  • Regular communication and engagement with customers to gather feedback and address concerns helps in continuous improvement and maintaining a competitive edge.

5. Cost Efficiency

  • To remain competitive, controlling costs throughout the manufacturing process is crucial at Calmet.
  • Implementing cost-effective production strategies, optimizing resource utilization, and managing overhead expenses helps minimize costs.
  • Continuous evaluation of cost drivers and exploring opportunities to enhance operational efficiency contribute to long-term profitability and competitive advantage.

6. Sustainable Manufacturing

Sustainable manufacturing focuses on minimizing the environmental impact and maximizing resource efficiency throughout the manufacturing process using the below commonly used techniques:

  • Energy Efficiency: Implementing energy-efficient measures like optimizing furnace operations, adopting energy-saving technologies, and utilizing renewable energy sources.
  • Waste Management: Implementing effective waste management techniques, including recycling and reusing materials, reducing waste generation, and implementing proper disposal methods.
  • Resource Conservation: Employing techniques to reduce water consumption, optimize raw material usage, and minimize emissions.
  • Supply Chain Transparency: Ensuring transparency and responsibility in the supply chain, such as sourcing materials from sustainable suppliers and monitoring the social and environmental impacts of the supply chain.

7. New Technologies

Innovative technologies can revolutionize the steel casting manufacturing industry, enhancing efficiency, quality, and customization capabilities. Some notable advancements at Calmet include:

  • 3D Printing: The introduction of 3D printing in forgings allows for complex shapes and design optimization, reducing material waste and lead times while enabling customization.
  • Automation and Robotics: Integration of automation and robotics streamlines production processes, enhances precision, improves safety, and increases productivity.
  • Data Analytics and AI: Leveraging data analytics and artificial intelligence can enhance quality control, predictive maintenance, and process optimization, resulting in improved efficiency, reduced costs, and enhanced product quality.
  • Augmented Reality (AR): AR technology can assist in training, remote maintenance and repair, and real-time quality assurance, improving operational efficiency and reducing downtime.

8. Industry Regulations

The forgings manufacturing industry is subject to various regulations, which ensure safety, quality, and environmental compliance. Key regulations may include:

  • Workplace Safety: Regulations governing occupational health and safety, including maintaining safe working conditions, providing proper protective equipment, and adhering to workforce safety standards.
  • Environmental Compliance: Regulations related to emissions control, waste management, pollution prevention, and resource conservation to mitigate the environmental impact of operations.
  • Quality Standards: Compliance with quality certifications such as ISO 9001 ensures that products and processes meet internationally recognized quality standards, fostering customer trust.
  • Supply Chain Traceability: Regulations and standards may require documentation and traceability of raw materials, ensuring responsible sourcing and avoiding materials with ethical or environmental concerns.

Keeping abreast of these regulations and proactively implementing compliance measures helps a firm maintain its reputation, enhance customer confidence, and demonstrate commitment to sustainability.

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