The forging manufacturing process utilizes metal that is hammered, pressed, or rolled under intense, localized pressure. The parts are shaped into high-strength components known as forgings.
Forged parts are stronger than the parts manufactured through other processes and are often used in applications where strength, reliability, and safety are critical. Once forged, components can be post-processed by precision CNC machining and surface finishing.
Zetwerk can design and produce forged components quickly and efficiently. Our team’s expertise in tool design and the use of industry-leading software ensures that production tools will produce high-quality components accurately. Our global plants enable us to rapidly prototype and produce components in a variety of materials.
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Zetwerk performs open-die forging between flat dies with no pre-cut profiles in the dies. This method involves moving the workpiece in order to shape it. This can be done with large parts that weigh over 150 tons and up to 25 meters in length. Forging can be done with various types of alloys, including ferrous, non-ferrous, and some exotics like age-hardening superalloys and corrosion-resistant refractory alloys. The shapes that can be created are limited only by the creativity of the manufacturing engineer. A benefit of this method is the ability to create prototypes in single-piece or low volume.
Open-die forgings impart similar grain flow orientation, deformation, and other beneficial characteristics when compared to closed-die forgings. Tooling and setup costs are eliminated with open-die forging, which is common for producing hardware tools and forged automotive components including crankshafts, drive shafts, and transmission shafts and gears.
Closed die forging is a process that uses two or more dies containing impressions of the desired shape. The forging stock is placed between the dies and undergoes plastic deformation, which results in a more complex shape with closer tolerances. This process can be used to forge most engineering metals and alloys, including carbon and alloy steels, tool steels, stainless steel, aluminum, copper alloys, and certain titanium alloys.
Forging can be hot (up to 1,260°C) or cold. Cold forging includes processes like bending, drawing, heading, coining, and extruding, which can create many different shapes. However, it requires stronger equipment and may need extra annealing steps.
Despite some drawbacks, cold forging is generally superior to hot forging in terms of dimensional control, product uniformity, surface finish, and contamination. However, it is not suitable for metals that are very strong, such as steel with high carbon content. For cost-effectiveness, cold forging is typically only used for parts that weigh 5 kg or less. Automated processing is possible for symmetrical parts that weigh up to 3 kg. Some of the most common materials used in cold forging include lower-alloy and carbon steels, and alloys of aluminum, brass, and bronze.
Rolled ring forging is a process where a thick, round piece of metal is punched to create a donut shape, which is then rolled or pounded into a thin ring. Ring diameters can start from less than one meter to over 10 meters.
We can post-process forged components to your exact specifications, including finish machining, heat treatment, and various surface treatments. Our quality-driven processes ensure that your forged parts meet your exact specifications in terms of material chemistry, dimensional stability, mechanical properties, and structural integrity.
Zetwerk has global quality expertise in FMEA, APQP, PPAP, SPC, and MSA and is AS 9100D & ISO 9001:2015 certified.
Zetwerk provides a full suite of services focused on reducing turnaround time and improving efficiency and value. Zetwerk delivers projects that are more cost effective and are brought to market sooner.
Zetwerk offers project management throughout the manufacturing process. After you create a PO, our team will guide you through each step. They will keep you up-to-date with the information you need to monitor production and share project information with internal stakeholders.
Once we receive your purchase order we’ll do a formal Design For Manufacturability (DFM) review with you and your team to ensure the design is optimized. This step will help prevent issues, reduce production time, and ensure the forged components meet your design and performance criteria.
Optimizing the tool design through a DFM is an often overlooked step; addressing this before manufacturing will save time and costs as well as enabling you to get to market faster.
A first-article inspection report (FAIR) is a part of any robust product development program. It is also critical to conduct detailed inspections to avoid out-of-tolerance components and rework for forged parts. Zetwerk’s process incorporates this essential step, giving you complete confidence in the parts you receive.
Global events of the early 2020s have demonstrated the importance of inventory management and supply chain resiliency. The traditional approach to JIT strains your ability to react to market or order fluctuations. Having a globally connected supply partner is an effective way to build resiliency and multi-source supply.
Zetwerk is your immediate and reliable solution for complete end-to-end manufacturing and supply chain services. We provide:
Experience the difference Zetwerk makes in your manufacturing process. Request a quote today for forging services or any other manufactured component.
