Heavy Duty Squeeze Cylinder

Q: In addition to the Heavy Duty Squeeze Cylinder, what other parts use the forging process?

A: Common metal parts that use forging processes include Forged Hub, Forklift Truck Support, and Rough Housing. Through the application of heat, forging refines grain pattern, resulting in high strength, ductility and improved resistance, making them more reliable. Forgings respond positively and predictably to heat and pressure, offering improved dimensional stability. By comparison, castings require tight controls during the melting and cooling processes, due to alloy segregation. The unpredictable response to heat, experienced in the casting process may result in finished parts that fail due to a lack of precision and inconsistent strength.

Q: Why does Forklift Truck Support use forging?

A: IMPROVED STRENGTH TO WEIGHT RATIO

In the closed die drop forging process, a metal bar or billet is heated before being placed in the die then hammered until the metal completely fills the die cavity. During this process of plastic deformation, the material's grain structure becomes compressed and aligned to the component shape which imparts greatly increased directional ­­strength with reduced stress concentrations in corners and fillets. Components manufactured this way are stronger than their equivalent machined-from-solid or cast parts.

STRUCTURAL INTEGRITY

Forging a component greatly reduces the possibility of metallurgical defects such as porosity or alloy segregation as found in some castings. This leads to reduced scrap, a uniform response to heat treatment, and predictable component performance in the field.

There is virtually no possibility of porosity being introduced during the forging process. Even this can be checked with a low-cost ultrasonic test after manufacture. The possibility of small surface cracks can be managed with a simple crack detection procedure towards the end of the process.

POST FORGING MACHINING

Parts can be machined post forging with no loss of quality because there are no voids or porosity in the fished article. Forging is often combined with machining for improved dimensional accuracy. This can also be achieved by post forge coining or sizing.

COST BENEFITS

Moving from machined-from-solid to forged components generates a saving in raw material usage. Starting from a near-net-shape forging can also reduce machining times. This means companies moving from machine-from-solid to machine-from-forging can generate enough capacity on their existing plant to save capital outlay on new machinery, as their business grows.

Customers often assume that the initial tool cost required for near net shape forging is prohibitive. In fact, forging dies and tools are quite simple in construction and are relatively low cost, making them viable even for jobs with low production quantities. This cost can be further mitigated by amortisation into the component piece price and even reclaiming pre-used die materials.

DIE LIFE

Closed die forging tools typically last between 5000 and 7000 cycles in more common carbon materials but can be as low as 100 cycles where very complex shapes are required in high-strength super-alloys. Die life expectancies are greatly reduced by sharp corners, material forge-ability, and very close tolerances. Some of these limitations can be offset by incorporating multiple impressions into the die design or by pre-forming the metal billet before putting it into the dies.

CYCLE TIMES

Forging cycle times are rapid: a typical forging is often complete within 10-30 seconds. However, some complex shapes require complex procedures where the level of skill and experience of the Stamper plays a key part.

DESIGN OPPORTUNITIES

This process is suitable for low-volume production as well as one-offs. This is because it produces parts with superior strength-to-weight properties that cannot be manufactured in any other way. Small volumes can be machined from solid, but they will have to compensate for reduced strength brought about by random grain alignment.

Undercuts are not possible in forging, however, it is possible to form undercuts and form joints with secondary forging operations. These processes can be used to make a huge range of component sizes and geometries.

Q: How to choose China forged hub factory?

A: Experience and Reputation: Look for a manufacturer with a solid reputation, client reviews, and a history of successful projects. View their portfolio of work, experience often translates into expertise and reliability.

Specialization: Consider the manufacturer's specialization and expertise in the type of forging you require. Different types of forgings (open-die, closed-die, impression-die, etc.) may require different skills and equipment.

Material Expertise: Ensure that the manufacturer has experience working with the specific materials required for your project, whether it's steel, aluminum, titanium, or other alloys.

Equipment and Capabilities: Evaluate the manufacturer's equipment and technology capabilities. Modern and well-maintained equipment can lead to higher quality and delivery of work on time.

Quality Control: Inquire about the manufacturer's quality control processes and certifications (such as ISO 9001). A commitment to quality is essential for producing reliable products.

Capacity and Lead Times: Determine if the manufacturer has the capacity to meet your production needs within your required timeframes. Delays in production can be costly.

Cost: Obtain detailed quotes from multiple manufacturers to compare pricing. However, don't make cost the sole determining factor, as quality and reliability are equally important.

Location: Consider the manufacturer's location and proximity to your facilities or distribution network. This can impact shipping costs and logistics.

Communication and Collaboration: Assess the manufacturer's willingness and ability to communicate effectively and collaborate with your team. Clear communication is crucial for project success.

References and Reviews: Ask for references and reviews from previous clients. This can provide insights into the manufacturer's track record and customer satisfaction.