Rotary Forging
At Elmet Technologies, we take pride in our advanced rotary forging capabilities, a key component of our innovative manufacturing processes. Using cutting-edge technology, we craft precision-forged bar products with unmatched efficiency, reducing material waste and machining costs. Our rotary forging expertise allows us to deliver exceptional results, even when working with expensive or high-performance materials.
By leveraging this sophisticated process, we maximize material utilization, significantly decrease waste, and often eliminate the need for extensive machining. Our CNC-controlled forging machines produce complex shapes with ease, supporting near-net shape production while maintaining the highest quality standards. We achieve this by precisely monitoring critical parameters such as power and temperature, showcasing our unwavering commitment to excellence.
Elmet’s rotary forging capabilities extend to a diverse range of materials, from soft metals like copper to high-performance alloys, including cobalt and nickel. This remarkable versatility ensures minimized end effects and reduced external diameter losses, enabling us to deliver top-tier products consistently.
Rotary Forging Process
Rotary Forging Equipment Data
- Force
- 200 Metric Tons/Hammer
- Billet Temperature
- Cold Forging
- 815 – 1375 degrees Celsius (1500 – 2500 degrees Fahrenheit) gas fired
- Input Sizes, Max diameter inputs are dependent on alloy.
- 28 – 160 mm (1.1 – 6.3 inch) diameters
- 813 – 2800 mm (32 – 110 inch0 lengths
- Output Sizes
- 28 – 152 mm (1.1 – 6.0 inch) diameters
Advantages of Rotary Forging
- 100% repeatability of the forging process with full CNC control
- Superior resultant material properties (strength & microstructure)
- Close tolerances and superior surface finish reduce yield lost to machining
- Temperature control enables long bars to be forged within narrow temperature windows
- Data acquisition is taken every second (force, speed, temperature)
- Extensive knowledge in the processing and metallurgy of a wide spectrum of materials and alloys.
- Experienced and responsive workforce
- Quick turnaround time
Rotary Forge Capabilities
Geometry
At Elmet Technologies, we can produce stepped and tapered products. The geometries depend on the tooling available and the workpiece properties at the desired forging temperature. Tooling can be manufactured for specific applications and requirements. The controlled rotary forging machine can hold a total forged tolerance of about 1 mm (0.040 inch).
Length
The maximum forged length for automatic unload is 6.25 meters (20.5 feet). If needed, longer lengths can be pushed manually to 6.85 meters (22.5 feet). Maximum lengths are dependent on material type and temperature requirements.
Furnace
Our gas fired furnace is 36 inch wide by 36 inch tall by 10 feet deep. We can maintain temperatures ranging from 1500 °F to 3000 °F
Advanced Rotary Forge Shapes
Forge Profiles: Bar & Tubing
- Rounds
- Squares
- Rectangles
- Hexagons
- Octagons
- Stepped Shafts
Quality Control Ensuring Consistency and Precision
At the heart of our forging process is a commitment to repeatability and reliability. We meticulously document and control every step to ensure consistent results from one production run to the next.
- 100% Repeatability: CNC programs are saved for every process, guaranteeing precise replication every time.
- Hammer Axis Precision: Achieves an impressive repeatability of 0.1mm over 100mm.
- Chuck Axis Accuracy: Maintains 1.0mm repeatability across an extensive range of 7250mm.
Our Custom Auxiliary Services
Explore our range of auxiliary services designed to meet your specific needs:
- Billet Sawing & Fabrication
- Cooling Solutions: Vermiculite Cooling, Air Cooling, Water Quenching
- Abrasive Blasting Services
- Cropping & Multing
- Scrap Management Solutions
- Extrusion Services
Your Partner for Unique Extrusion Solutions
Elmet Technologies works closely with customers to develop unique extrusion solutions for all applications. We can extrude a wide range of materials and collaborate with our customers to create tailored solutions that meet their specific needs. Our team is committed to delivering precision and quality in every project.