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Maxplus Enterprise
Closed Die
forging, Drop forging, Hot forging, Upset forging components from
India
Manufacturer exporter closed die forging
[ drop forging / hot forging ] ,
upset forging from Carbon steel, alloy
steel and stainless steel.
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AboutUs |
Infrastructure |
Process |
Products |
Quality |
Contact |
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Introduction
We are India based
manufacturer and exporter of Closed die forging [
drop forging /
Hot forging ] for carbon steel, alloy steel and stainless steel. We
manufacture quality drop forging components [ hot forging ] &
Upset forging
as per your specification and samples . Our main product line
includes hot forgings and upset forgings for automobile industry, agricultural implements, flanges
and pipe fittings, electric transmission / pole line parts, earth
mover parts. We also supply
customized forgings as per buyers drawings / samples. We can handle
parts from 100 grams to 15 kilograms, moreover well equipped advanced
forge shop, die shop, metal testing laboratory, Cutting & Shear
shop, an efficient heat treatment facility with machine shop,
ensures fast delivery
of your part and also making us a one-stop source for all your
hot forging, upset forging needs.
We work with a sole
objective of helping your business with customized drop forging /
hot forging
/ upset forging solutions. We have built a reputation of being a forward thinking,
plan-design-build company, committed to our quality objective of
satisfying our clients to the fullest extent. We have an optimum mix
of manpower and sophisticated technology to provide you customized
forgings. With seasoned expertise in forging industry, we know how
to get the job done. We believe in delivering quality products , on
schedule at a competitive price and We believe in developing and
forging all business relationship on the foundation of Quality,
Honesty and Trust. Please visit other sections of our website to
gather more details and incase of your requirements for hot forgings
using drop forging method or upset forging please feel free to contact us. |
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About Us |
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We are manufacturer of
closed die forging, upset forging. We adopt drop forging and hot
forging methods to forge carbon steel, alloy steel and
stainless steel.
Maxplus Enterprise [ forgings ] has a long standing reputation in
forging industry. We stand with our commitment to quality,
innovation and customer orientation. Quality forged products coupled
with delightful forged relationship with our clientele have made us
leader in our industry. Our customers pose high faith in us and we
take extra efforts to match their expectations. We deal in closed
die forgings of carbon, alloys and stainless steel, products ranging
from 1 to 15 Kilogram/Piece by weight.
Established in 1995, the management and their team comprises of
dedicated professionals from the field of engineering and business
management. This team derives ideological and financial support from
promoters who are established and experienced in industry and
business. Initially we started forging auto parts and flanges,
within two years of business the market has started accepting us as
a reliable supplier of forgings. After about 6 years of local market
experience we looked toward expanding our market reach by exporting
our products. Currently we export our products Europe, USA.
In our glorious journey, we have gradually moved up the success
ladder, thanks to sound management system, ethical practices and
promoters' acumen in the industry. We have expanded ourselves
qualitatively and quantitatively and today we cater to the needs of
varied customers falling in diverse range of industries such as
automotive ancillaries, engine manufacturing, agricultural
implements, electric transmission parts and others. Strictly
dedicated to regimented practices, we have always catered to orders
of different magnitudes, shapes and sizes with specific time frame
and quality requirements.
We are situated at Rajkot [Gujarat State- India ] , the city well
known for top quality engineering products across India. The city is
well connected with road, rail and air. It is about 45 minutes away
from Mumbai via Air route. Moreover well known ports like Kandla
port, Mundra port is also about 250 Kms from our city.
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Our infrastructure consist of advanced forge
shop, die shop, metal testing laboratory, Cutting & Shear shop, an
efficient heat treatment facility with machine shop, ensures fast
delivery of your part and also making us a one-stop source for all
your forging needs.
Forge shop consist of Drop Hammer (2 Ton & 1 ton), Pusher type
furnace [500 Kgs per Hour] ,Mechanical Power Press, Heat Treatment
Furnace box type. Die shop is equipped with Vertical Milling
machine, Electro discharge, Lathe machines, shaping / drilling
machines , air compressors, die grinders, welding machines. Cutting
shop is equipped with Band-saw Machines, Billet Shearing Machines.
Quality control equipments includes megna flux for crack detection,
Verniers, ,Bevel protector , Universal testing machine, impact Test
Impact test equipments, Brinnel/Rockwell hardness testers.
Incase of finished products or machined parts, we have tie-up with
very competent machining suppliers with large fleet of latest CNC
Machines and each machined part is thoroughly inspected for
dimensional accuracy. Radiography test / ultrasonic test is
outsourced to the best and most competent units identified by us.
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The process of
forgings starts from designing
facility through both, Computers and Manually facilitates us
preparing the best modeling for part and tooling development.
Dies & Tooling
An In-house Die-shop equips us for fabricating all types of dies and
tooling, using VMC , lathes and other tools. Dies are produced using
Wooden Pattern Graphite Electrode. Full sets of templates are fitted
on sinking of the die for rigid dimensional checks and inspection.
Raw Materials
Materials is procured from reputable approved Steel Mills in form of
Cast Billets, Blooms, Rolled Billets etc. , in various Size as per
the requirement of the final product. Raw Materials inward process
automatically checks for the quality of the Material. Materials of
different types are stored separately with color codes marked, to
Facilitate full traceability and avoid material mix-ups.
Cutting
Most cutting of raw material is done with the help of Shearing
Machines and Band-Saw Machines. Color codes are marked on Cut pieces
and are stacked separately with a banner fixed over each stack so as
to identify the materials grade and also the final product to which
they are meant.
Heating
Cut pieces are heated in Pusher type forging Furnaces fitted with
Temperature Controller. The pieces are carried to the forging
hammers through over-head traveling Mono Rails.
forging, Coining & Trimming
The process of forging is carried out on Pneumatic forging Hammers.
The metal is shaped to a part by Hammering the hot cut piece between
the Top and the Bottom dies fixed on the Hammer. The finished
product through this process is much more reliable for strength and
quality than a similar product produced by casting, pressing or
machining.
Post forging Operations
Depending upon the specific requirements of the end use of forged
components, forgings undergo further processes such as Heat
Treatment, Shot Blasting, Magnaflux crack detection. etc. We have an
In-House facilities for these processes.
Machining
We are situated at the place where we have a number of ancillaries
engaged in doing the machining jobs. Whenever, required we can out
source CNC Machining, Drilling, Threading, Capping and Grinding
etc., from your quality-approved ancillaries.
Quality Assurance
Quality checks are inbuilt in the processes to maintain complete
control at each stage of the cycle. It begins with receipt of raw
material, die development, cutting, forging which includes hot
inspection, secondary operations and final inspection. Samples are
checked for dimensional accuracy and metallurgical soundness.
Samples of hot forgings are inspected at intervals for visual
forging defect and dimensional accuracy. 100% crack detection is
carried out on magnaflux machine and hardness is finally tested to
meet with the requirements. |
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Hot & Upset Forging
Products
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Generally the forging industry don't limited
themselves to a fixed product line, but rather make a selection of
products on the basis of the infrastructural facilities which one
have. No doubt that generally each forging unit specialize in
forging some parts due to their experience. We manufacture hot
forging / upset forging using carbon, alloy and stainless steel from 100 grams to 15
kilograms [in some cases the weight may reduce or increase to some
extent due to nature or complexity of designs]. We supply closed
die, upset forging [drop forging/ hot forging] or upset forging
products as per your specification or samples. We supply forging in
forged , semi-forged or finished condition.
Automobile Components
: Our flagship products when we entered forging business include auto part range. Hot
forging auto
parts includes u j cross, steering yokes, axel stub, gear blanks,
connecting rods, propeller shaft components, forks, rocker arm , tow
ball, crankshaft, compressor crankshaft, camshaft, gear components,
clutch forks, tractor parts. We never limit ourselves to parts which
we manufacture. We supply customized forged parts as per buyers
drawings and samples.
Flanges & Fittings :
Our product range also includes various kind of flanges [ forged or
machined ] and pipe fittings. Our range includes weld-neck, slip on,
threaded, socket weld, lap joint, blind. The diameter size of
flanges 1/2" - 5"NB. Fittings include Elbows, T Joints, Y Joints,
Couplings. The diameter size which we can handle is 1/4" - 2"NB. The
material standards which we follows are ASTM, DIN, JIS, GOST, etc.
Electric Transmission Parts / Pole Line
Parts : We also manufacture pole line accessories which includes
ball clevis, anchor shackle, socket clevis, clevis eye, socket eye,
hook, suspension bracket, arching horn, dead end pin [ steel clamps
], bolt hook, horn holder. Moreover we always manufacture parts to
your specification / samples.
Earth Mover Parts : We also manufacture
earth mover [JCB] teeth point and side cutter.
Upset forging : Upset
forging, also called hot heading, is a process by which the
cross-sectional size of a bar is increased, either at an end or at
some point along its length. It is done on specially designed
upsetting machines, using closed dies to control size and shape. We
manufacture upset forged products as per buyers drawings and
samples. We also supply hot forge / cold forged fasteners. |
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Quality |
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Quality - A commitment, A
habit, A routine, A way to growth is how we define it. Quality is
the only factor in todays world which can decide the growth of any
business organization. In order to grow and have exponential growth
rate one needs to provide consistent quality at reasonable price. We
at Maxplus understand this and always follow it, we always believe
in delivering products which surpass customers expectations.
Quality checks are inbuilt in the process to maintain complete
control at every stage of forging cycle. Raw material selection, die
development, cutting and forging processes are carried out in
pre-specified fashion. Every prototype and parts batch go through
rigorous quality checks. Samples are checked for dimensional
accuracy and metallurgical soundness. Samples of hot forgings are
inspected at regular intervals for visual forging defects and
dimensional accuracy. When required, 100% crack detection is carried
out on magnaflux machines and hardness is finally tested to meet
with the requirements.
Moreover continuous training of our technical staff is also
undertaken from reputed institutes in order to know latest
innovations in our industry and we always try to improve our
production process in order to increase quality and efficiency as
well as to cut down production cost. |
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Contact
For All your closed die forging / upset forging requirements [
drop forging / hot forging ] for carbon steel, alloy steel or
stainless steel please feel free to contact us at
email address : forge [at]
maxplushotforging.com
[note : please replace [at] sign in above
email with "@" sign] |
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THE FORGING
PROCESS
When metal is hot, it is in a soft and pliable
condition allowing it to be easily formed under pressure without
breaking. This process is called forging.
Metal is strongest in the direction of its grain flow. Machining
cuts through the grain, thereby weakening the metal. Forging causes
the grain to flow in the shape of the part. Therefore, forgings are
stronger than machined parts. Also, since the shape of the part is
created by pressure, not cutting, much less metal is lost in the
process. This means that parts with complex shapes can be formed and
mass produced by forging more economically than by machining.
- Drop forging is a mass production technique
which hammers the metal between two dies. Half of the die is
attached to the hammer (upper section) and half to the anvil (lower
section). The hot metal is placed in the lower half of the die and
struck one on more time with the upper die. This forces the metal to
flow in all directions, filling the die cavity. Excess metal
squeezed out between the die faces is called flash or flashing.
After the forging is completed the flash is cut off in another press
with a trimming die.
Upset forging, also
called hot heading, is a process by which the cross-sectional size
of a bar is increased, either at an end or at some point along its
length. It is done on specially designed upsetting machines, using
closed dies to control size and shape.
Typically, dies have several stations, and the parts are formed
progressively by moving the parts from one die station or cavity to
another until the forging is complete.
Heads of bolts, valves, single and cluster gear blanks, artillery
shells, and cylinders for radial engines are examples of parts made
by upset forging.
This same process, when performed cold, is called cold heading .
Cold heading makes possible the economical mass production of
fasteners; such as nails, screws, bolts, hinge pins, and rivets. |
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