How products for the world of industry are made

The whole manufacturing process is a highly sophisticated adventure. At the beginning we have our engineers and developers who use state-of-the-art software to design the structure of forgings and select the technology used for their production. They also product parts for new platforms of cars, engines, transmission gears, as well as for other vehicles such as trucks and for hydraulic engines. They carry out virtual simulations of key production operations and develop a prototype of the new forging. The complex production process includes:

Construction and development

Our engineers work with the latest 3D software in order to simulate the process of shaping and the design of optimal technologies for the production of the desired forging. In cooperation with our largest customers we develop new, structurally highly demanding forgings, including the selection of materials. The goal of our work is to always find an optimal solution to a given request. These are often complex solutions which take into account technical, economic as well as logistical aspects. We use the following data formats and software in our development process:

CAD/CAM - NX 11
Team Center - Management of technical documentation
Forge - Shaping process simulation
Správa technické dokumentace - Team Center

Production of tools and moulds

Precisely manufactured forms guarantee stable conditions for the production of forgings. The forms are manufactured exclusively on modern CNC machines using HSC technology. We use high-quality, vacuum-hardened materials with surface nitration. The production of tools also includes inspection of measurements on 3D CNC checkpoints. We use the following devices to produce tools:

Machining centers - Trimill, ZPS Tajmac
Turning-lathe centers - ZPS, MAS, YCM
Measurement of tools - Zeiss

Forging

We process all types of steel materials including micro-alloyed steel, and use these to make products weighing between 0.1 and 30 kg. We use modern sawmills and scissors for accurate and efficient material separation. We also have access to state-of-the-art technology for pass-through lines with fully automated operation. Forging itself is secured on twelve production lines equipped with forging presses.

Finalization

We perform all types of thermal processing of forgings, whereas material heating is carried out exclusively via induction heating with continuous temperature monitoring. Alternatively, we process our parts using our well-proven specialized external suppliers (dying, zinc coating, galvanizing, phosphate coating). We usually carry out the following types of surface finishing:

Thermal processing
Blasting
Calibration and final inspection
Výstupní kontrola

Machining

We have access to all conventional technology for the processing of forgings (machining as well as surface finishing). We also carry out highly precise production of rotating as well as non-rotating parts made of forgings for the automotive and engineering industries. We work the following modern CNC centers:

CNC centers – MAKINO, GROB, CHIRON
Turning-lathe machines – EMAG, OKUMA, LEADWELL

Quality

We apply modern quality inspection systems and have access to excellent management, use all state-of-the-art methods and tools for quality control of our whole production process from the purchasing of material through continuous monitoring of production up to final inspection before dispatch. As a manufacturer of safety parts, we are fully equipped with all the appropriate technology and organization of our processes.

Dimension measurements - 3D CNC Zeiss, 3D Axiom
Metalography - Struers, Olympus
Material monitoring - Spectrometer Belec, Delta X
Magnatest - Foerster
Horizontal defectoscope UNIMAG
Hardness measurements - Struers micro-hardness testers


The basic principle of forging was discovered 5000 years ago - shaping metal at high temperatures allows us to transform it into the desired shape while improving its mechanical properties. However, the industry has undergone radical changes since then. Empirical knowledge is still key, but today it is also often replaced by exact data, procedures and simulations. A blacksmith's hammer, forge and furnace were replaced by automated shaping lines. files and drills were replaced by highly precise CNC machines. However, the personal touch of a master forgesmith remains essential. And being part of one of the oldest branches of industry can be seen as a true privilege. Only true personalities and team players can ensure the continuous development of the field, one that has held an irreplaceable position in our technical history for thousands of years.

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