Brooks Forgings Ltd, a leading UK manufacturer of forged, machined, and fabricated components, is proud to announce a major £170,000 capital investment, centred on the installation of a state-of-the-art 75,000 Nm high-torque geared-drive pre-stressing and scragging system at our West Midlands manufacturing facility.
As the only high-capacity machine of its kind in the UK and Western Europe, this installation successfully restores a vital lost sovereign capability.
The specialist pre-setting process has historically represented a gap in the UK supply chain for certain heavy-duty torsion-bar applications, requiring components to be processed through fragmented or overseas routes. Brooks Forgings' new capability brings this critical stage back into a controlled UK manufacturing route.
The investment marks a significant milestone for our heavy engineering division. By bringing this specialised process on-site, Brooks Forgings has streamlined its production routes and strengthened its ability to provide commercial and industrial customers with an integrated UK manufacturing solution for high-stress components.
The new state-of-the-art 75,000Nm torsion testing and pre-setting machine at Brooks Forgings Ltd.
| Capability | Specification |
|---|---|
| Maximum applied torque | 75,000 Nm |
| Maximum component diameter | Up to 80 mm |
| Maximum component length | Up to 3 metres |
| Drive system | High-torque geared drive |
| Cycle control | Programmable multi-stage sequences |
| Recorded information | Torque, angle, dwell and permanent set |
| Target sectors | Defence, rail, off-highway and specialist vehicles |
The Missing Link in Heavy Component Production
Heavy-duty torsion bars are subjected to extreme operational loads and fatigue. To establish the required permanent set and help ensure dimensional stability during operation, these components undergo a controlled pre-setting process, commonly known as “scragging”. The component is subjected to a controlled torsional load beyond its initial elastic range, establishing the required permanent set and beneficial residual-stress condition within the material.
Live readouts display critical information, such as current cycle stage, remaining dwell time, twist angle and applied load. Permanent set angle is also displayed once the sequence is complete.
Live line charts detail the applied torque and angle for each cycle, providing a visual indication of how the bar responds as it progresses through the pre-setting cycle and reaches its final permanent-set condition.
Inside the machine: The torsion bar at its starting position before the pre-setting cycle. White line for visual purposes only.
Inside the machine: The torsion bar after testing, resting at its approximately 30-degree permanent-set angle. White line for visual purposes only.
The new £170,000 machine enables Brooks Forgings to perform this critical final stage of production in-house. When combined with our upset forging capability, precision CNC machining, advanced heat treatment, spline grinding, shot peening and non-destructive testing (NDT), the new system enables Brooks Forgings to provide a fully managed and traceable manufacturing route for heavy torsion bars up to 80mm in diameter and 3 metres in length.
Defence Supply Chain Capability
The investment further strengthens Brooks Forgings’ position within the UK defence supply chain, supporting the manufacture and replacement of critical torsion-bar components for tracked and specialist vehicle platforms. Combined with our established quality systems, component traceability and specialist heavy-engineering capabilities, the new pre-setting and scragging facility provides customers with a resilient UK manufacturing route for critical components, supporting the long-term availability of parts for legacy vehicle platforms.
Precision Automation and Full Traceability
To provide consistent and verifiable quality control, the new system is fully programmable to execute multiple test phases, varying twist angles and velocities, and complete duty cycle sessions. Furthermore, operational data for every individual torsion bar is automatically captured and stored against the unique identification marking stamped onto each component, providing a complete digital record of the pre-setting cycle.
Every torsion bar produced at Brooks Forgings Ltd is uniquely marked to provide complete traceability.
Our micro-percussion marking system is digitally controlled, configured to meet the requirements specified by the customer.
Completed torsion bars for tracked fighting vehicles, ready for final packing and shipment.
Streamlining the Supply Chain
With global supply chains facing ongoing logistical challenges, the ability to secure critical heavy engineering components through an integrated, domestic route has become a major priority for industrial sectors.
"For too long, heavy engineering projects have had to rely on fragmented supply chains to source fully processed, high-strength torsion bars," said Richard Lee, Marketing Manager, Brooks Forgings Ltd.
"This £170,000 investment significantly changes what we can offer customers. We have closed the loop. From the initial raw material forging right through to the final permanent set, we are providing a highly resilient, faster, and fully traceable manufacturing alternative. We aren't just scaling up our capacity; we are expanding our technical capabilities to meet the most demanding industrial requirements."
As a company committed to high standards of quality and manufacturing excellence, we are fully aligned with modern industrial strategies, focusing on security of supply, component quality, and localised precision engineering.
For technical enquiries relating to new or replacement torsion bars, pre-setting and scragging requirements, or the manufacture of other high-strength forged components, contact the Brooks Forgings engineering team on +44 (0)1384 563356 or submit an enquiry via our contact page.
