Process
Our integrated manufacturing process ensures controlled production, consistent quality, and precision at every stage of forging.
The manufacturing process begins with detailed engineering and design evaluation. Our team studies component drawings, material specifications, and application requirements to create optimized forging designs that ensure strength, dimensional accuracy, and efficient material utilization.
Forging dies are developed in our dedicated die shop equipped with VMC Cosmos CVM-1050, heavy duty lathe machines, radial drilling machines, milling machines, and tool grinding equipment. Each die is precisely machined and inspected to ensure accurate forging cavities and long die life.
Before production begins, raw materials are inspected and tested to verify quality standards. Proper material verification ensures the forged components meet the required mechanical strength and reliability for critical industrial applications.
Raw material bars are cut into precise billet sizes using fully automatic bandsaw machines with cutting capacity up to 175 mm. Accurate billet preparation ensures consistent forging weight and dimensional control.
Billets are heated to the required temperature using a 400 KW Induction Billet Heater with Three-Way Accept/Reject System Furnace, ensuring uniform heating and process control. The heated material is then forged using a 2 Ton Belt Drop Hammer, shaping the metal into the desired form with high strength and structural integrity.
Excess material is removed using a 300 Ton H-Type Trim Press to achieve accurate component shapes. After forging, components undergo controlled heat treatment processes to enhance mechanical properties such as hardness, durability, and wear resistance.
Forged parts are cleaned through shot blasting to remove scale and surface impurities. Fettling operations refine the surface finish and remove any unwanted projections, preparing the components for further processing.
Each component undergoes detailed quality inspection to ensure dimensional accuracy and compliance with customer specifications. Strict quality control at every stage ensures reliable and consistent forged products.
For applications requiring high precision, components undergo CNC machining to achieve tight tolerances and accurate finishing, making the parts ready for industrial use.
Efficient production operations are supported by EOT cranes of 2 Ton and 5 Ton capacity, ensuring safe material movement across the facility. The plant is powered by a 1400 KVA On-Load Transformer, along with 40 HP rotary screw compressors and cooling towers (80TR & 50TR) for reliable production operations.