Viking Forge and Transvalor USA Closed Die Forging

Case study Viking Forge - Closed Die Forging with Transvalor FORGE® Digital Solution.

Challenge: Optimizing disc-brake manufacturing through digital simulation with FORGE®.

Solution: A three-step forming process to minimize die stress and prevent material folding.

The Company

Viking Forge is a hot forging job-shop in northeast Ohio.  In an industry that is changing so rapidly, with increasing global competition, and shorter product life cycles, Viking Forge maintains highly technological and competitive advantages.

The company's precision closed die forging capabilities are dedicated to leveraging advanced technology to advance the science of forging. Employing state-of-the-art equipment and processes, including PLC controls, quick-change tooling, and automated production systems, the company produces the highest quality near-net hot forging at competitive pricing compared to conventional forge shops. The company specializes in forming carbon, micro-alloy, and stainless steel in a range of 1 to 100 pounds. Serving a diverse customer base, the company handles a wide variety of parts such as gears, wheel hubs, trucking hitch rings, and valve components.

Challenge

Optimizing disc-brake manufacturing through digital simulation with FORGE®. Challenge Solution A three-step forming process to minimize die stress and prevent material folding. Navigating the complexities of disc-brake manufacturing presents a significant challenge, particularly in the intricate process of shaping the material from its initial cylindrical billet to the final disc-brake form. At each stage of this transformation, including the progression from a cylindrical billet to a flattened pancake and finally to a ring-like shape before achieving the desired disc-brake form, there are inherent risks. These risks include the potential for excess stress and wear on the dies, as well as the susceptibility to material folding, which can compromise the integrity of the final product.

Solution

A 3-hit process was implemented for a new disc-brake job.  In these 3 forming stations, the material moves from its cylindrical billet, then a flattened pancake, to a shape that is essentially a ring, and finally its disc-brake form.  and machine time, manufacturing materials and machine time, and an overall savings in engineering resources.  An early iteration of a tooling design is shown here, and shows that a fold can be expected. FORGE accurately represented our manufacturing process. The initial weight trial and subsequent production runs matched the simulation results.  

Forming much of the material into a ring type shape is key to avoiding excess stress and wear on the dies.  The ring can be sensitive to material folding and this highlights more of the great benefit of FORGE.  The iterations/trials can be shaken out digitally; without consuming tool & die materials Testimonial This forging sequence and design produced tooling that has not shown signs of early wearing, the part is free of fold as the one seen in early simulation attempts, and the finish station is extruding material into the outboard and inboard flash which relieves excessive stress on the tooling while filling the cavity.

Testimonial

We switched to Transvalor Forge for its intuitive interface, fast simulations, and excellent support. Forge seamlessly integrated into our workflow, accurately predicting manufacturing outcomes and boosting our design accuracy. Notably, Forge reduced process cycle time by two seconds for a critical part, thanks to its predictive capabilities. Over thirteen years and three software switches, Forge consistently stood out for its precision and ease of use. Transvalor Americas' responsive support was crucial to our successful transition. Their training programs were invaluable, making Transvalor our top choice for enhancing manufacturing processes. Forge's ability to optimize design validations and streamline workflows was a game-changer, minimizing waste and energy consumption while maintaining quality standards.

Damon Stocker, Design Engineer & Pat Walsh, Engineering Manager

TRANSVALOR AMERICAS CORP - 405 W Superior Street - Suite 601, Chicago, IL 60654

Phone: +1 312-219-6029 - Email: marketing@transvalor.com - www.transvalorusa.com