Alry receives a blueprint, we proceed to make the master die. A plaster
cast is made from the master die for approval. After the plaster cast
has been approved, the forging dies are made, using the master die as a
stock is ordered for the manufacture of the forgings. The completed
forging dies are then mounted in a hammer of sufficient size to form the
forgings. The bar stock is cut into lengths appropriate to the
dimensions of the finished forging. The lengths of material are heated
in a forging furnace.
length is pulled from the forging furnace by the hammerman using tongs,
and placed in the blocker area of the forging die. The hammer is
activated for several blows.
the rough formed forging is moved to the finisher area of the forging
die. The hammer is activated once again for several blows. At this
point, the forging is fully formed, but, still has a flash attached to
it. The flash is the excess material around the formed forging.
forged piece is removed from the forging dies by a trimmerman and is
placed in a trim press. A few blows are necessary to remove the flash
from the forging. The completed forging is then placed in a cooling bin.
The cooling bin may contain liquid, to comply with the specifications
provided on the blueprint supplied. Once cooled, the forgings are placed
in a wheelabrator with fine steel shot to clean off scale and
discoloration formed in the forging process.
the forming of forgings, inspections are done on the first forging lot
to assure tolerance specifications. Additional inspections are made
according to the size of the production run. Inspections are also
performed on a percentage of the run before and after wheelabrating, and
prior to packaging for shipment.