Electrical Upset Forging Machine Installed Further Increasing Our Manufacturing Capability
Brooks Forgings Ltd has expanded its manufacturing capabilities by acquiring an electrical upset forging machine, further increasing our forging capacity.
The fully refurbished machine is now fully commissioned and operational at our Lye, Stourbridge site.
The machine was acquired from the Tinsley Bridge Group, the last of their remaining upset forging capability. It was primarily used for torsion and anti-roll bar production, for which Brooks Forgings is already well-known and a prominent market leader in UK manufacturing.
Electrical Upset Forging is a process that uses both electrical resistance heating and hydraulic pressure to produce a large gathering of material from a single heat, at the end of a relatively small diameter bar. The starting raw material can be up to 60mm in diameter, using metals with exceptional electrical conductivity, such as steel, stainless steel, and exotics.
Tooling is less comprehensive, and the setup time for production is greatly reduced, resulting in lower production costs. The carbon footprint per component is also significantly reduced, as only the required amount of energy is used and utilises our solar power reserves, unlike with continuous oil or gas-heated furnaces used in conventional upset forging processes.
A fully integrated computer system allows our operators to store and recall specific forging parameters, creating a library for both bespoke customer components and generic forms based on material type, length, and diameter. This offers full repeatability, and less experienced operators can use the machine with minimal training.
For larger volume projects, we are confident that we can integrate robotics, making the process fully automated with minimal operator input.
This process is used to produce a wide range of components, including Torsion Bars, Transmission Shafts, Flanged Shafts, Eye Bolts, Headed Bolts, and Tie Rods.
This strategic investment reinforces Brooks Forgings’ commitment to becoming the most versatile manufacturer in the UK.
