FORGING
Forging is a fabrication process that involves shaping metal using localized compressive forces while the metal is in a solid state. This method produces components with exceptional strength, structural integrity, and consistency, making it highly efficient with minimal material waste. However, forging is not suitable for creating complex geometries or internal cavities and may be limited by the size of the equipment used. It is also not compatible with all alloys.
Types of forging
OPEN DIE FORGING
Suitable for large, heavy parts like shafts, cylinders, and discs where metal is deformed between simple shaped dies (not enclosed).
CLOSED DIE FORGING
Ideal for high-volume production with excellent strength and precision where metal is forced into a closed die cavity to shape the whole part.
ROLL FORGING
Used to create tapered or cylindrical parts, enhancing grain structure and material strength where metal bars are passed through grooved rolls to reduce thickness & increase length.
UPSET FORGING
Increases the diameter of the workpiece by compressing its length, used for parts like bolts.
PRESS FORGING
Applies slow, continuous pressure rather than impact forces which allows for better control of deformation.
Produces parts very close to final dimensions, minimizing post-forging machining.
PRECISION & NET
SHAPE FORGING
Common products
Commonly used to create aerospace & automotive parts - crankshafts, connecting rods, rocker arms, camshafts, gear blanks, drive shafts, propeller shaft yokes, brake levers, turbine discs, engine mounts, compressor parts, wing roots, landing gear cylinders,
& struts.
MACHINING
Our comprehensive machining services, including CNC machining, boring, and grinding, enable us to produce high-quality, precision-engineered components for a wide range of industries. Whether you need small, intricate parts or large, robust structures, our skilled team and advanced equipment ensure that we meet your exact specifications with efficiency and excellence.
Types of machining
CNC MACHINING
CNC (Computer Numerical Control) machining is a subtractive manufacturing process that uses computerized controls to operate machine tools such as lathes, mills, routers, and grinders. The process involves removing material from a workpiece to create the desired shape, based on a digital 3D model. CNC machining is known for its precision, efficiency, and ability to produce complex geometries with high accuracy.
BORING
Boring is a machining process used to enlarge and refine existing holes in a workpiece. This process employs a single-point cutting tool or a boring head to achieve greater accuracy and a superior surface finish compared to the initial drilling or casting. Boring can be performed on various machine tools, including lathes, milling machines, and specialized boring mills.
GRINDING
Grinding is a precision machining process that uses an abrasive wheel or belt to remove material from a workpiece, resulting in a smoother surface or the desired shape. This process is essential in manufacturing for achieving high precision, tight tolerances, and superior surface finishes. Grinding can be performed on various materials, including metals, plastics, and ceramics, making it a versatile and valuable process in many industries.
Common products
Commonly used to create gears, bearings, engine components, transmission gears, and suspension parts, turbine blades, engine mounts, landing gear parts as well as other industrial equipment needs & custom parts.
EXTRUSION
Extrusion is a versatile metal forming process used to create long parts with uniform cross-sections by forcing material through a die. There are two main types: hot extrusion and cold extrusion.
TYPES OF EXTRUSIONS
HOT EXTRUSION
Hot Extrusion involves heating the material, typically a metal billet or ingot, above its recrystallization temperature before forcing it through a die using a hydraulic press. This method is ideal for producing complex cross-sectional shapes and profiles from materials like aluminum, copper, steel, titanium, and nickel alloys. It offers high-quality surface finishes and is efficient for high production volumes, but it comes with high equipment and operating costs and potential for surface oxidation.
THE PROCESS
Pre-heating
The metal billet is preheated to the desired working temperature in a furnace.
Loading
The heated billet is loaded into the extrusion press container.
Pressure application
A ram or plunger applies immense pressure, forcing the hot metal to flow through the die opening.
Extrusion
The extruded metal takes the cross-sectional shape of the die as it exits.
Finishing
The extruded product may undergo cooling, straightening, stretching, or heat treatment processes.
COLD EXTRUSION
Cold Extrusion is performed at room temperature or slightly elevated temperatures and is used to produce high-strength components with excellent surface finishes. This process increases the strength and hardness of the extruded material through cold working and avoids oxidation issues. It is suitable for small to medium-sized parts made from aluminum, copper, brass, mild steel, stainless steel, and other ductile metals. However, it is limited to softer metals and can encounter issues like cracking if not properly lubricated.
THE PROCESS
Placement
The metal billet or slug is lubricated and placed into the extrusion chamber.
Loading
A punch or ram applies immense pressure, forcing the cold metal to plastically deform and flow through the die opening.
Extrusion
The extruded metal takes the cross-sectional shape of the die as it exits.
Finishing
The extruded product may undergo additional cold working, heat treatment, or finishing processes
Common products
Commonly used to create aluminum profiles for construction & transportation industries, copper & brass rods, tubes, wires, steel & titanium components, aluminum cans, collapsible tubes, cylindrical components, copper & brass fittings, hardware, decorative items, steel bolts, shafts, & other fasteners.
FABRICATION
With welding, cutting, and bending capabilities, our fabrication services produce high-quality, precision-engineered components for diverse industries. Whether you require small, intricate parts or large, robust structures, our skilled team and state-of-the-art equipment ensure we meet your exact specifications with efficiency and excellence.
Types of fabrication
WELDING
Welding is a fabrication process that joins materials, usually metals or thermoplastics, by using high heat to melt the parts together and allowing them to cool, causing fusion. This process is essential in creating strong, durable joints and is widely used in various industries & is essential for assembling large structures and frames.
CUTTING
Cutting is a fabrication process that involves removing material from a workpiece to achieve the desired shape and size. Various cutting methods include laser cutting, plasma cutting, waterjet cutting, and mechanical cutting (sawing, milling).
BENDING &
FORMING
Bending is a fabrication process that involves deforming a material, usually sheet metal, to create an angular shape. This is typically done using press brakes, rollers, or other bending machines.
Common products
Commonly used to create wind turbine components, solar panel frames, mounting systems, structural steel beams, columns, trusses, girders, chassis components, machine frames, enclosures, piping systems, & conveyor systems