PROBLEM + SOLUTIONS = $ SAVINGS
RINGS
Flame cutting a ring from plate is not economical when meeting material requirements.

  • Flame cutting, all corner stock and the full center slug is lost even though you pay for it.
  • As desired thickness of the ring increases, availability of plate sizes and grades drastically decreases.
  • Uni-directional grain flow of plate increases susceptibility of ring to fatigue failure.
A custom forged ring allows greater versatility and improved quality while reducing material cost.

  • The forging process moves and shapes material to ordered ring size with minimal material waste.
  • Required ring thickness has no effect on the virtually limitless combinations of sizes and grades available.
  • The porosity and laminations sometimes encountered in plates is eliminated with a custom forged ring.
  • Contoured grain flow within forged ring yields combination of strength, toughness and fatigue resistance.
30% MATERIAL SAVINGS
Material=4340
Finished Size=46 5/8″ O.D. X
  26 1/4″ I.D. X 4 1/8″ FACE
Materials Needed to Produce=
  Forging=2,015 lbs.
  Plate=2,865 lbs.

56% MATERIAL SAVINGS
Material=1021
Finished Size=22 5/8″ O.D. X
  17″ I.D. X 9″ FACE
Materials Needed to Produce=
  Forging=700 lbs.
  Plate=1,580 lbs.

Bars & Shafts
Matching a solid bar to form a step down causes expensive use of material, labor and time.

  • When machining the step down, all excess material, as shown here, is lost.
  • Machining time, tool life and freight costs are expensive.
  • Grain flow within the bar is exposed when machined, thus making the material more susceptible to fatigue failure.
Custom forging the bar to form a step down lowers the cost for a value added part.

  • Forging requires less starting material, thus saving cost on excess material waste.
  • Less machining saves money, time and tool life while producing a closer-to-finish shape.
  • Freight and handling costs are lowered because the forged step down weighs less than the bar.
  • Contoured grain flow within forged step down yields greater impact and directional strength.
64% SAVINGS
Forged Sizes=18 1/4″ O.D. X
  16 1/2″ Long, Step 11 1/4″ O.D. X
  8″ Long, Step 6 3/4″ O.D. X
  48″ Long
Weight=1,935 lbs.
Bar Size=18 1/4″ O.D. X 72 1/2″
Long
Weight=5,375 lbs.

49% SAVINGS
Forged Sizes=4″ O.D. X
  13 1/16″ Long, Step 6 1/2″ O.D. X
  9 3/4″ Long, Step 4″ O.D. X
  19 13/16″ Long
Weight=205 lbs.
Bar Size=6 1/2″ O.D. X 42 1/4″ Long
Weight=400 lbs.

Hubs
When hub shapes are achieved through machining solid bar stock or flame cutting plate, waste is an expensive part of the process.

  • When machining a shape from solid bar or flame cutting plate, all excess material is lost. See the illustration below.
  • Machining or flame-cutting means costly machine time, lowered tool life, and increased freight costs.
  • Most importantly, the uni-directional grain flow of both bar and plate increases the likelihood of fatigue
Custom forging of hub shapes improves quality, lowers material costs and offers maximum flexivility.

  • As it requires less material from the start, forging saves on both material and freight.
  • The forging process requires simple tooling yet can produce virtually limitless combinations of single or double hub sizes.
  • Reduces machining saves time, labor, and tooling costs and forging produces a nearer net shape.
  • The optimum combination of strength, toughness, and fatigue resistance in the hub is achieved by the continuous grain flow which comes through forging.
59% MATERIAL SAVINGS
Forged Sizes=4″ O.D. X
  20″ Face, Hub on side 9″ O.D. X
  4 1/2″ Projection
Weight=346 lbs.
Plate Size=20″ Square X 7 1/2″
Thick
Weight=850 lbs.

43% MATERIAL SAVINGS
Forged Sizes=18 1/4″ O.D. X
  3 7/8″ Face, Hub on side 10 5/8″
O.D. X 6 1/8″ Projection with a 3″
I.D. through
Weight=421 lbs.
Bar Size=18 1/4″ O.D. X 10″ Long
Weight=741 lbs.