You are here:

Technical preparation of production

We can handle even more demanding forgings

The production process begins with our development team, which deals with the construction and technological processes in the manufacture of die forgings.

Our engineers work in modern 3D software, such as: Creo Parametric 3.0, Forge NxT 2.1, Autodesk Inventor and Autocad Mechanical, with which they can find optimal design solutions for even more difficult forgings.

We work in accordance with valid regulations and standards of ČSN, EN or according to customer's technical requirements.

We develop tailor-made solutions

We develop technologies and manufacturing processes for die forgings and rolled rings from 0.2 to 40 kg. We also process the design of forging and clamping tools for forging and cutting presses.

We will be glad to develop an individual solution for you.

What materials do we work with?

Structural steel: St 37-2, St 50-2, St 52-3, St 60-2, St 70-2

Low-alloy and high-alloy steel: 16MnCr5, 20MnCr5, 42CrMo4, 50CrV4, 18CrMo4

Bearing steel: 100 CrMnSi6-4, 100Cr6

 

Suppliers of input material:

Třinecké železárny – Czech Republic

ASCOMETAL – France

Петросталь –Russia

CMC Zawiercie S.A. – Poland

Huta StalowaWola S.A.


12 forging lines

After technical preparation and separation of materials, we come to the forging. We process materials with a weight of between 0.2 and 40 kg up to a diameter of 400 mm and a length of 500 mm in small-scale and large-scale production.

We have 12 forging lines designed for both vertical and horizontal forging, and we also have automated pre-rolling and rolling machines.

What forging lines do we have?

Vertical forging presses

1 x press with a forming force of 10 MN (1000 t)

2 x press with a forming force of 16 MN (1600 t)

3 x press with a forming force of 25 MN (2500 t)

2 x press with a forming force of 40 MN (4000 t)

2 x press with a forming force of 63 MN (6300 t)

Horizontal forging presses

2 x press with a forming force of 8 MN (800 t)

Pre-rolling machines

1 x transverse forging cylinder ULS 55

3 x forging cylinders

Rolling machines

2 x radial roller up to a diameter of 400 mm

2 x radial roller up to a diameter of 250 mm

1 x radial roller up to a diameter of 600 mm


Normalization and isothermal annealing

We perform soft annealing in two ten-ton chamber furnaces, we have two lines for normalization annealing, two lines for refining in water and isothermal annealing, and two lines for refining in oil.

The forgings are treated on 8 heat treatment lines, on continuous and chamber electric resistance furnaces, with horizontal and vertical induction heating.


Calibration, grinding and final surface treatment

The entire process is completed by final surface treatment, which includes dirt stripping in drum jets, calibration and straightening of cold forgings, grinding, control of surface defects and other necessary modifications.

What equipment do we have?

For calibration, we use a press with a forming force of 20 MN, a hydraulic press with a forming force of 0.3 M, three band blasting machines with a batch weight of 600 kg and one with a weight of 1200 kg. We also have a machine for controlling surface cracks, and a wet magnetic particle testing device that we use for magnetic powder control.


Product quality is regularly checked

Quality control is performed throughout the manufacturing process from material input, interoperative control to final control and metallographic verification in the laboratory. The high quality of the products is ensured by regular testing and the use of FMEA process methods, establishing and observing control plans, sampling procedures and statistical control methods with machine and process verification.

Control room equipment

In our control room you will find classic gauges, templates and products for dimensional and shape control of forgings, including optical pyrometers, which we use to verify compliance with customer requirements. The hardness of the forgings is measured using HPO 3000 BRINELL, BRIRO BEH-1 and HP 250 (Rokwell) hardness testers. In order to verify the parameters of machined bearing rings, the control room is equipped with workshop meters with electronic transmission of measured data to the PC and a ConturoMatic CV 300 conturograph.

Specific control activities

Control and detection of surface defects by the magnetic powder method for materials and forgings up to a maximum length of 750 mm is carried out using a DEUTROFLUX UHW 750 S defectoscope.

Control of ferrous materials by the magnetic inductive method (control of chemical composition, crystalline structure of material, hardness) is carried out using a MAGNATEST D 3.623 system.

Metallographic laboratory and certificates

We have a metallographic laboratory in which we are able to perform tests and verification according to the following standards:

DIN 50602 - Metallographic examination; microscopic examination of special steels using standard diagrams to assess the content of non-metallic inclusions

ČSN EN ISO 643 - Steels -- Micrographic determination of the apparent grain size

ISO 6687, ČSN 42 0449 - Steels - Determination of depth of decarburization

SEP 1520 - Microscopic examination of carbide structure in steels by means of diagram series

Tests that we do not perform are covered by an external certified laboratory.

Our company is certified according to the ČSN EN ISO 9001: 2009 standard with a certificate from BUREAU VERITAS


We produce new tools, but we also restore old ones

We produce and restore forging tools in the die forging shop, where we also have our own hardening shop for all types of heat treatment. We use tool steels to produce new tools, the choice of steel is determined by the type of stress on the individual tool.

Restoration of worn tools is carried out by overlaying and subsequent machining or reducing the shape. For overlaying, special overlaying electrodes are used. We use conventional machines up to a diameter of 1000 mm, including a CNC lathe for machining tools up to 350 mm in diameter.

We have machine equipment, which can also repair even the largest parts of forging tool clamping systems.


We perform everything from turning to grinding

At Zetor Kovárna we focus on the turning of bearing rings, and other types of machining can be performed in our parent company. We perform the following types of machining:

Milling, drilling, threading, turning, planar and rotary grinding, gear and grove milling, gearing, grooving, stretching, gear grinding, and heat treatment etc. We have more than 450 machine tools and heat treatment lines.