CUSTOM FORGED PRODUCTS

Western of Texas Forge & Flange has the team experience and work history for the forging of industrial custom products such as rings, discs, blocks, cylinders, tubesheets, and valve bodies. This involves several critical engineering and manufacturing processes designed to ensure the final product meets specific mechanical and dimensional requirements. Below is an overview of our process and approach to all custom work orders.

Design and Engineering Specifications

Material Selection

The first step in the forging process is choosing the appropriate material based on the product’s intended use, environment, and mechanical properties. Common materials include carbon steel, alloy steel, stainless steel, and non-ferrous metals (like aluminum and titanium).

For example, components subjected to high temperatures or corrosive environments (e.g., valve bodies or tubesheets) may require materials with specific chemical compositions to resist corrosion and wear.

CAD Modeling

Detailed Computer-Aided Design (CAD) models are created based on the customer’s specifications. These models define the dimensions, tolerances, and critical features of the component.

Finite Element Analysis (FEA) or other simulation tools may be used to simulate stress distribution, ensure material optimization, and predict potential failures.

Billet Selection and Preparation

Raw Material Procurement

Forging starts with selecting billets (solid metal pieces) of the required material and size. The billet size and shape depend on the final product.

Heating

The billets are heated in a furnace to a temperature suitable for forging. Typically, this temperature ranges between 900°C and 1250°C for steel, depending on the material. The heating must be uniform to avoid uneven mechanical properties in the final forged product.

Forging Process

Depending on the shape and size of the desired product, different forging methods are used.

Open Die Forging

Open die forging involves deforming the heated billet between flat or shaped dies, allowing the material to flow freely. This process is typically used for large, simple shapes like discs, blocks, and cylinders.

Large components like valve bodies and blocks are often forged using this method, as it provides excellent control over material grain flow, leading to stronger components.

Ring Rolling

For products like rings, a billet is punched to create a hole in the center, then placed between rollers that reduce its thickness while expanding the diameter.

This method is highly effective for producing seamless rolled rings with superior mechanical properties.

Upsetting

Upset forging is used for components like blocks, cylinders, or valve bodies, where increased thickness is required in specific areas. The billet is compressed to “upset” or thicken certain sections while maintaining the overall length.

Tooling and Die Design

Precision Tooling

Custom tooling and dies are created based on the CAD model to shape the component. These dies must be manufactured with high precision to ensure dimensional accuracy and consistency in the final product.

Material Flow Optimization

Engineers optimize the die design to control material flow during forging, ensuring that the desired grain structure is achieved. A well-designed die minimizes internal stresses and enhances the strength of the forged part.

Heat Treatment

Normalizing or Annealing

After forging, the part is often heat-treated to refine the grain structure, relieve internal stresses, and improve mechanical properties like toughness and hardness.

Processes like normalizing, annealing, quenching, and tempering are employed depending on the material and intended application of the forged product.

Quenching and Tempering

In critical applications like valve bodies and tubesheets, quenching (rapid cooling) and tempering (reheating to a lower temperature) may be used to enhance toughness, hardness, and wear resistance.

Machining and Finishing

Rough Machining

After forging, the product typically undergoes rough machining to remove excess material and bring it closer to the final dimensions.

CNC Machining

Precision machining using Computer Numerical Control (CNC) technology is employed to achieve the exact dimensions, surface finishes, and tolerances specified in the design.

For components like valve bodies or tubesheets with complex geometries and precise sealing surfaces, CNC machining is crucial.

Drilling and Tapping

For products like tubesheets, drilling of multiple holes with precise spacing is critical, as these will house tubes in heat exchangers or boilers.

Valve bodies often undergo additional operations like drilling for passageways and thread tapping.

Quality Control and Testing

Non-Destructive Testing (NDT)

Forged components undergo various non-destructive testing techniques, such as ultrasonic testing, radiography, and magnetic particle inspection, to detect internal defects (cracks, voids, etc.).

Dimensional Inspection

Dimensional checks are performed using CMM (Coordinate Measuring Machine) or laser scanning systems to ensure the final product meets design specifications.

Mechanical Testing

Hardness testing, tensile testing, and impact testing may be conducted to verify the mechanical properties of the forged product.

Hydrostatic Testing

In applications like valve bodies and tubesheets, hydrostatic or pressure testing may be done to ensure the component can withstand operating pressures.

Final Inspection and Certification

Once the forged component passes all quality checks, it undergoes a final inspection. Certification and documentation (e.g., material test reports, NDT results) are provided to verify compliance with industry standards such as ASME, ASTM, or ISO.

Any additional surface treatments or coatings (e.g., anti-corrosion coating) are applied based on customer requirements.

Shipping and Delivery

After successful testing and inspection, the forged products are packaged carefully to avoid damage during transportation. Large industrial products like valve bodies or cylinders may require custom crating or protective packaging.