FORGINAL industrie's production site

The workflow of your orders and the production processes

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Forginal Industrie
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design-office–CAE-FORGINAL-industrie

Creating forged stainless steel parts

The design office transforms your drawings of finished parts into drawings of as-forged parts.

All your parts are reproduced in 3D using Solidworks™ so that they can be manufactured in the forging process. Our design office checks several technical points, including dimensional tolerances, form tolerances, radii, drafts, positioning of the parting line, etc.

Once you have validated the forging drawings, the design office uses the CAE system to finalise the creation of the metal parts by creating the forging and trimming tools. It creates a 3D simulation of the machining path of each tool to ensure the optimum visual appearance of the parts after forging.

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How is a forging tool created?

The rules for designing a forging tool are not limited to a single forming cavity in a die. Various studies are necessary in order to :

  • Ensure all your technical requirements are incorporated when the metal parts are created
  • Ensure the high quality surface appearance of the parts after forging
  • Optimise the machining time of the forging dies (tools)
  • Improve the service life of the tools in order to reduce production costs

Project manager

The project manager is responsible for your project from beginning to end, from the design of your forged part right through to its series production.

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Expertise

  • Creation of forged 316L stainless steel parts or other materials (drawings and tools)
  • Use of their technical expertise to optimise your projects
  • Monitoring and validation of forging trials
  • Monitoring the manufacturing process and compliance with logistics lead times

CAE team

There are 5 people in the design office. All the members of the team are trained in the use of design and machining software and have technical qualifications. They all have at least 5 years’ professional experience working in a design office and using CAE in an industrial environment.

CAE equipment

  • FORGINAL industrie’s technical rules :

These are general rules governing tool design. They are defined in-house by the technical teams and represent the company’s experience gained over 35 years in the industry.

They are a mixture of traditional forging rules and FORGINAL industrie‘s own specialist skills.

  • SOLIDWORKS™ software
  • MASTERCAM™ software
  • Forge 4 software (forging simulation)

Laurent BAUDONNAT

Project Manager – Design Office

With FORGINAL industrie for 5 years

I worked in plastics processing for 15 years before taking up my position with FORGINAL. I worked in the toolmaking design office, like I do here. The main difference in my work is the materials used. Forging is very interesting. What I particularly like about my job is that there is always something new. It is not monotonous here!

Methods department – responsible for the overall process

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The methods department checks the feasibility of your forging projects. It pays particular attention to :

  • The dimensions and tolerances specified on your drawings
  • The raw materials (suitability for forging, ease of supply, quality, etc.)
  • Standards (forging, raw material, final appearance of parts, testing and checking)
  • The specifications and requirements for your parts

Following a full analysis, the Methods Department determines the manufacturing process for each of your parts.

It defines the appropriate production facilities, and details the subcontracted operations and the tests to be carried out during and after production.

Series production is always preceded by forging trials to validate the process defined by the process planners. Their specialist experience and their constant interaction with all the other teams in the company ensure that the production processes are optimised.

Methods Department

This is made up of 2 people with technical and mechanical training. They have over 20 years’ experience in forging.

Sébastien FERVEL

Methods Manager

With FORGINAL industrie for 22 years

I like being able to track all the parts we make at FORGINAL industrie. The methods department is always involved from the very start of projects: we establish the technical rules so that the part is produced in accordance with best practices, both now and in the future. We have to have a good knowledge of the inner workings of the company and we work closely with all the company's departments.

Tooling department: a company within the company

The Design Office sends the CAE drawings and data to the Tooling Department for it to create the machining programmes. Several tool assemblies are required to make your forged parts :

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Inserts

Parts of the tool in which there is generally a rough forging and a finished forging. This is the part in which your parts are forged. These inserts are mounted directly on our drop hammers.

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Trimming tooling or punches

These are used to cut off the flash (the part of the material remaining around the part after forging).

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Specific tools

Depending on the shape of the part and the various requirements of your projects, we machine various additional items, such as machining fixtures, inspection gauges, bending tools or marking dies, etc.

And at FORGINAL industrie we go even further to optimise our production tools:

We manufacture our own insert holders, tool carriers and weights in-house, which are fitted and maintained by our own specialist personnel.

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Steps in toolmaking

1/ Creation of the machining programmes
2/ Machining of the blocks of raw materials (it can take up to 30 hours to machine an insert)
3/ Testing of each component subassembly of the final tool
4/ Assembly and mounting of tooling
5/ Forging, trimming and sizing trials

Quality control of the tools and logistics planning

  • The quality of the tools is checked after each forging run to ensure that production is carried out under perfect conditions.
  • Each tool is cleaned, polished and stored in readiness for the next time it is used.
  • Re-machining (refurbishment) is scheduled, if necessary. Planning starts in the Tooling Department. Each subassembly is planned independently. All subassemblies must be made and supplied on time to ensure that manufacturing keeps to the required schedule.

Equipment in our Tooling Department

  • 2 HSM (high-speed machining) centres
  • 2 3-axis machining centres
  • 1 FANUC wire erosion machine
  • Various milling, piercing, turning and spark erosion machines
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Tooling team

This is made up of 10 people with mechanical engineering/machining qualifications. They all have at least 15 years’ professional experience, most of them at FORGINAL industrie.

Jean-Luc BROS

Tooling Manager

With FORGINAL industrie for 37 years

I have seen all the developments in tools, from manufacturing by hand right through to numerical control! I like everything about my job, and I like metal. I love engineering, it's a real passion. I spend a lot of time on it, both at home and at work

FORGINAL industrie’s expertise

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All hot forging operations are precisely defined by the manufacturing process defined by the methods department.

The recommended process and production tools are tailored specifically to your specifications.

Here is what takes place in a traditional forging process :

  • Drop forging (rough and finish)
  • Hot or cold trimming (depending on the size of the part)
  • Hyperquenching (for certain types of part, in particular those made of stainless steel)
  • Shot-blasting (to remove the scale adhering to the part)

Research & Development

FORGINAL industrie applies its know-how to innovation. This commitment has enabled it to develop very high quality forging :

  • Guaranteed tolerances among the tightest on the market, excluding sizing
  • Thin parting lines for a better visual appearance of your parts
  • Standardisation of the tools for ease of assembly and adjustment of the forging tools, and optimisation of production times
  • One of the best qualities of finish on the market, in particular in terms of the surface of the parts
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Forging Equipment

  • 2 Montbard board power hammers (600 kg and 1,200 kg)
  • 2 compressed air power hammers (2,500 kg and 3,600 kg)
  • one 750 tonne press
  • New generation induction heaters with temperature traceability during production
  • 4 hot trimming presses
  • 1 steel shot-blasting machine
  • 1 pneumatic hammer for drawing

Forging team

This is made up of 14 people including 2 team leaders and one forge manager. The average forging experience of the staff is 10 years.

Fikri OZKAN

Drop Forger

With FORGINAL industrie for 22 years

I am still learning, even after 20 years! I have followed the advances and changes in techniques. We don't have fixed workstations. We know how to do everything, from drop forging to trimming and drawing. That's what I like.

Finishing : “cold” workshop

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Cold trimming

We use a trimming tool to remove any residual flash created during drop forging. Cold trimming is for small parts which cannot be trimmed while hot due to a risk of deformation or of creating incipient breaking points when the part is cooled. This trimming also avoids any risk of burrs and is cleaner, especially for very thin parting lines.

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Calibration

This is used to refine the thickness or shape tolerances of a part.

Sizing is a cold operation, carried out using a complete tool (which takes the total shape of the part) or a partial tool (just for sizing a sensitive part).

Sizing causes cold working, which increases the surface hardness of the metal part.

Markings

There are several options for marking parts :

  • Directly in the hot forging tool: most frequently, marking in a cassette
  • During adjustment, after forging on the cold part: most frequently, indented or punched marking
  • Tool with marking die and punch
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Assembly

FORGINAL industrie can create assemblies on sets of parts, as you require. Our teams have bending or pressure machines for any type of finish. We can also offer you specific packaging on request (individual protection of parts, packages by weight, etc.). Please feel free to request a quotation.

Machining

FORGINAL industrie has been working in partnership with a number of machining companies for many years, so that we can give you the finish you need.
Our subcontractors are listed and inspected annually to validate the quality of their services from all aspects (technical, quality, price, logistics, etc.)
Our partners are located in the immediate vicinity of FORGINAL industrie, which greatly simplifies contact and means that the production lead time is not affected.

Finishing equipment

  • 4 trimming and bending presses
  • one 750 tonne sizing press
  • 2 abrasive polishing belts
  • 1 straightening machine
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Finishing team

5 people including 1 foreman. Click on the link above to see the photos of our teams and details of their experience.

Jean-Luc BOREL

Cold Finishing Department Manager

With FORGINAL industrie for 34 years

Forging runs in my family. I never thought about doing anything else, it was a natural thing to do. I have been manager of the cold parts finishing workshop since 2005. It needed someone who knows what they're doing to carry out the final operations before dispatching the parts to the customer. I know what needs to be done for everything to run smoothly

Testing & dispatch | goal : optimum quality

Zero defects due to the rigorous testing system

Each testing programme is defined after a risk analysis: according to the end use of the part, your requirements and past manufacturing at FORGINAL industrie.

The testing programme is formalised in the context of a quality assurance plan. This plan is submitted to the customer for validation for each part. Any significant modification of the production and/or testing process is also systematically submitted to the customer.

Inspection Department

We carry out numerous tests on your parts and we adapt them to your specifications for each part. The main tests we carry out are listed below :

Dimensional validation

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The critical dimensions of your parts are checked throughout the manufacturing process, to prevent any deviation. The functional measurements are checked prior to dispatch, against your drawing and specifications.

The testing programme that is devised takes account of the requirements of your drawings and specifications, to ensure the parts comply fully with your expectations.

A variety of tools are used for these tests (callipers, profile projectors, gauges, and manual and automatic 3D machines).

Dye penetrant inspection

This is carried out on 100% of the surface of the parts by staff with COFREND (French confederation for non-destructive testing) level 2 qualifications. The quantity of parts tested is defined by the customer. By default, 5 parts are controlled per production batch.

The tests are carried out in accordance with standards NF EN 10228-2 and ISO 3452-1 with sensitivity level S3 products. The dye penetrant inspection line is an SREM line specifically for final NDT (non-destructive testing).

Technique: The parts are dipped in a red penetrant liquid, and then a powder developer is applied to their surface. The developer absorbs the penetrant, and reveals any surface defects under white light

Magnetic particle testing

This is carried out on 100% of the surface of the parts by staff with COFREND (French confederation for non-destructive testing) level 2 qualifications. The quantity of parts tested is defined by the customer. By default, 5 parts are controlled per production batch.

The tests are carried out in accordance with standard NF EN 10228-2 with sensitivity level S3 products, from the same standard.

This test can only be carried out on magnetic parts, which excludes all parts made of titanium, stainless steel and specific grades such as Duplexes, Monels, Hastelloy, etc.

Technique: The parts are sprayed with a product containing fluorescent particles and then subjected to a magnetic field. The particles are attracted to any surface defects, which can be seen under UV light.

Mechanical and micrographic tests

  • Hardness
  • Micrographic structure
  • Grain size

Additional tests

FORGINAL industrie has a comprehensive list of approved subcontractors for carrying out your additional tests.

All our subcontractors are COFRAC (French accreditation body) accredited. They can carry out tensile testing in accordance with ASTM E8/E8M or ISO 6892-1.

Full traceability is assured, and the service provided is controlled using precise specifications. Other tests can be carried out on request, according to our customers’ specific requirements.

Packing – Dispatch

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We can offer various types of packaging, to meet your logistics and storage requirements as closely as possible. We can offer the following options :

  • Pallet box (dimensions: 750 X 750 X 400 mm)
  • Packing in small cardboard boxes of less than 20 kg (dimensions 300 X 160 X 170 mm) in a pallet box
  • Wooden box (dimensions: 1,000 X 600 X 400 mm)
  • Packing in bags of less than 25 kg in a pallet box
  • Packing in VpCI bags (anti-rust protection)
  • Gitterbox with cover for protection against adverse weather conditions

For economic reasons, we offer pallet boxes as “standard” packaging.

But we are of course happy to consider any option that would be most suitable for you. Please feel free to tell us what you need. (Individual protection of parts, packages by weight, etc.)

Dispatch :

FORGINAL industrie chooses its transport partners with care and assesses their logistics performance annually. We only work with European transport specialists. Pick-ups are made daily to ensure just-in-time deliveries to our customers.

Inspection Department equipment

  • 1 dye penetrant inspection line, sensitivity level S3 (SREM)
  • 1 Crysta-Apex automatic 3D machine
  • 1 Crysta+ M544 manual 3D machine
  • Micrographic testing equipment
  • 1 universal hardness testing machine
  • Various measuring tools: callipers, profile projector, measuring column, etc.
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Testing / Quality team

This is made up of 8 people, 2 of whom are COFREND (French confederation for non-destructive testing) level 2 qualified dye penetrant inspection and magnetic particle testers. The average experience of the team is over 15 years. It is a multi-skilled team, which is a real strength.

Brigitte VIALLET

Manager of the Inspection and Dispatch Department

With FORGINAL industrie for 11 years

Our equipment is up-to-date and enables us to carry out in-depth testing, especially with the 3D measuring machines, vision measuring and profile projectors. For this job you need to have a solid grounding in metallurgy, heat treatment and measuring systems. I am still learning every day, and it's really interesting!

Sandrine BRUGÈRE

Testing technician

With FORGINAL industrie for 12 years

I got into forging by chance, but since I've been here I've done loads of training courses for the job. I love it. I was trained by my "older" colleagues. When they retire, I hope to take their place, so that I can take my turn to train new employees.

FORGINAL industrie :

  • Covers 29,000 m²
  • The buildings and grounds are owned by FORGINAL industrie.
  • The adjoining plots of land mean that FORGINAL industrie can build future extensions without any restrictions.