COMPETENCIES

HOT FORGING

Hot forging is one of the oldest and most widely used methods in metalworking. This technique involves heating metal to high temperatures and then hammering it into the desired shape. The temperature of the metal is critical in making the material malleable, typically conducted within the range of 1200-1300°C. Skilled craftsmen can achieve complex and precise designs by meticulously controlling the metal’s temperature and the forging process.

Stages of the Hot Forging Process:

Raw Material Cutting:

Long shafts (6m) from approved suppliers are inspected by the Incoming Quality Control (GKK) and then cylindrically cut using fully automated shears and saws.

Hot Forging:

The cut material is heated to approximately 1200°C in fully automated induction furnaces and then hot-formed in eccentric forging presses ranging from 400 to 4,000 tons.

Sandblasting:

Scale removal and surface roughness reduction are performed on the forged parts using fully automated rubber and steel drum sandblasting machines, with capacities ranging from 300kg to 750kg.

Cold Calibration:

The cold calibration process is carried out using hydraulic and eccentric presses to bring the sandblasted parts to their final dimensions.

Crack Control:

Surface cracks are inspected by applying a special liquid under ultraviolet light before the final quality control stage.

ALUMINUM FORGING

Aluminum forging involves shaping aluminum alloys through impact or pressure forces. This process can be performed hot, semi-hot, or cold. Hot forging, in particular, enhances the strength of aluminum and achieves the final shape and dimensions required. For instance, critical components such as engine parts, suspension components, and wheels in the automotive sector are produced using aluminum hot forging. This method provides a balance of high strength and light weight, thereby improving performance and fuel efficiency.

Basic Steps of the Aluminum Forging Process:

Heating: Aluminum alloys are heated to the appropriate temperature before forging begins. Hot forging is performed above the recrystallization temperature of the metal, ensuring that the aluminum softens sufficiently to take on the desired shape.

Shaping: The heated aluminum is shaped using either open or closed dies. Open die forging is utilized for simpler and rougher shapes, while closed die forging is employed for more intricate and precise components. Our facility handles hot forging with a capacity ranging from 400 tons to 4,000 tons.

Cooling and Processing: Following the forging process, the parts are cooled, and any burrs are removed if necessary. Additionally, heat treatment may be applied to enhance surface quality and achieve the desired mechanical properties.

MACHINING

Machining is a fundamental aspect of modern industrial production, centered on the principle of removing material in small pieces, known as chips, using cutting tools to achieve the desired shape. The primary goal of machining is to produce parts with high precision. This method can be executed with exceptional accuracy using advanced technological equipment, such as CNC (Computer Numerical Control) machines.

Our machining capabilities encompass a wide range of processes, including turning, milling, drilling, grinding, gear cutting, and broaching. These processes enable us to deliver not only finished components but also provide our customers with enhanced convenience and cost efficiency.

The machining unit is equipped with the most advanced technologies and equipment. Fully automated machining lines are extensively employed to achieve higher production rates, increased productivity, and consistent product quality.

In our machining facility, we consistently achieve tight dimensional tolerances and precise surface finishes for a variety of products used across different sectors. Our facility is equipped with 9 CNC lathes, 6 CNC milling machines, 4 horizontal machining centers, and 1 broaching machine, enabling us to perform high-quality machining that meets customer expectations.

HEAT TREATMENT

Our 1,350 m² heat treatment facility offers an extensive range of heat treatment capabilities. With an annual capacity exceeding 5,000 tons, the facility is equipped with 3 Ipsen Atmosphere-Controlled Furnaces, 5 Aichelin Rotary Furnaces, Aichelin Continuous Isothermal Annealing Furnaces, Nitrex Nitriding Furnaces, Steremat Induction Benches, and Ony Atmosphere-Controlled Continuous Hardening Furnaces. The processes conducted include Tempering, Case Hardening, Isothermal Annealing, Induction Hardening, Stress Relieving, Carbonitriding, Nitriding, and Nitrocarburization. In addition to providing heat treatments for a wide variety of chain components, our facility also performs heat treatments for Topçesan hot forging parts and nitriding proceses for hot forging molds.

In our facilities, which feature two in-house laboratories, conduct Rockwell, Brinell, and Vickers hardness measurements, chemical analyses of steels, macro-microstructure examinations, and internal structure inspections of steel. The strength tests for chain and forging parts are conducted using vertical and horizontal tensile testing devices, with detailed reports provided to our customers in compliance with the IATF 16949 and ISO 9001 Quality Management Systems. Additionally, the CQI-9 heat treatment process evaluation standard is rigorously inspected by our quality unit.

With half a century of experience in the sector, our company remains committed to innovation and strategic investments. Our comprehensive range of heat treatment furnaces enables us to respond swiftly to industry needs, and our experienced team provides exceptional service in our heat treatment facilities.

MOLDING

1. Forging Model

At this stage, engineers and designers analyze the part model and technical drawing to create a forging model tailored to meet the customer’s needs and expectations. This is accomplished using computer-aided design (CAD-CATIA) software. The design process accounts for the thermal and mechanical stresses that may occur during forging, ensuring that the internal and external geometry of the mold and the technical drawing align precisely with the final shape of the part. This design phase is critical for the functionality and production efficiency of the mold.

2. Mold Design

Upon receiving customer approval, the mold design process begins. This stage is crucial for adapting the forging model to production requirements. Mold design is carried out with careful consideration of the materials and techniques that will be used during production. Once the mold design is completed, the performance of the molds is tested using QForm simulation programs. These simulations help identify and address potential issues such as folding or non-filling, ensuring the design is fully optimized before production begins.

What is a Hot Forging Mold?

A hot forging mold is a vital tool in the metalworking industry, widely used for shaping metal at high temperatures. During this process, the metal is heated above its recrystallization temperature and then placed into the mold to achieve the desired shape. This elevated temperature allows the metal to be shaped more easily and enhances the internal structure of the material, making this method particularly suitable for producing parts that require high strength and durability. The hot forging mold remains an essential technique in modern metalworking.

3. Mold Production

The approved mold design is then executed on CNC milling machines. These machines enable the production of molds with high precision and complex geometries, offering faster and more accurate results compared to traditional manual methods. Throughout the production process, quality control tests are conducted at each step to verify the accuracy of the mold’s dimensions, surface finish, and material integrity. Once production is complete, the mold undergoes heat treatment and hardening to ensure it can withstand high temperatures and pressure. Following these steps, the molds are integrated into the production line, and mass production begins.

In our facility, we conduct the hot forging mold production process with meticulous planning, precision machining, and rigorous quality control. Our equipment includes 10 CNC milling machines, 3 universal milling machines, 3 universal lathes, 3 plunge erosion machines, and 2 grinding machines. Each stage of this process is essential to maintaining the high standards of quality and customer satisfaction that define our production capabilities.

ENGINEERING AND R&D

RFQ (Request for Quotation) Process

The RFQ process begins with managing customer requests. Initially, the technical drawings and specifications provided by the customer are thoroughly reviewed. A feasibility study and cost estimation are then conducted based on this information. Following customer nomination, project planning is initiated, and the new product commissioning process starts. During this stage, coordination is maintained to ensure that all tasks related to molds, apparatus, and fixtures are executed according to the project plan.

Upon completion of these steps, the Production Part Approval Process (PPAP) is presented to the customer, adhering to the specified quality and delivery timelines. The PPAP is a crucial step for obtaining customer approval and transitioning to mass production. Once product approval is granted, the process is monitored with a Standard Operating Procedure (SOP) + 3 months follow-up. This follow-up ensures stable production processes and preemptively addresses potential issues.

The part revision or change process is managed in response to new customer demands or required modifications to existing products. Revisions are made according to updated technical drawings and specifications, and the relevant processes are reassessed. Revised or changed parts undergo the PPAP process again, with mass production commencing only after receiving customer approval. This approach aims to maintain high levels of customer satisfaction and product quality.

Design

The preparation of forging and processing models is a critical phase in the production process. These models are meticulously designed to meet customer requirements. Mold designs, control equipment, and processing equipment are developed based on the prepared data, aiming for optimal efficiency and adherence to quality standards.

Upon completing the design process, the part undergoes detailed analysis using advanced analytical software. This analysis evaluates the part’s durability, strength, and performance characteristics, identifying potential issues and areas for improvement. This stage ensures that the part meets the desired specifications as a final product.

The preparation of forging and machining models, along with the design of necessary equipment based on these models, is executed with precision. Detailed examinations using analysis programs ensure that parts meet quality and performance expectations. This comprehensive approach enhances customer satisfaction and maximizes production effectiveness and efficiency.