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Specialist in-house torsion bar pre-setting, scragging, and testing services at our West Midlands manufacturing facility.
As the only high-capacity machine of its kind in the UK and Western Europe, we successfully eliminate supply chain fragmentation and restore a vital sovereign capability for heavy-duty defence, commercial, and industrial applications.
Centred around our state-of-the-art 75,000 Nm high-torque geared-drive system, this capability delivers a fully integrated, controlled UK manufacturing and processing route for high-stress suspension and actuation components.
Specialist pre-setting has historically represented a gap in the UK supply chain for heavy-duty torsion-bar applications, often requiring components to be processed through overseas routes. By bringing this critical stage completely in-house, Brooks Forgings streamlines production routes and strengthens our ability to provide commercial, industrial, and defence customers with a secure, fully managed UK solution.
| 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 Science of Scragging & Pre-Setting
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.
Our advanced 75,000Nm system allows us to perform this critical final stage of production directly in-house. When combined with our upset forging capability, precision CNC machining, advanced heat treatment, spline grinding, shot peening, and non-destructive testing (NDT), we provide a fully managed and traceable manufacturing route for heavy torsion bars up to 80mm in diameter and 3 metres in length.
Supporting the UK Defence & Heavy Engineering Sectors
This capability significantly 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 and component traceability, our pre-setting and scragging facility provides customers with a resilient UK manufacturing route, ensuring the long-term availability and operational readiness of parts for legacy vehicle platforms.
Precision Automation and Full Traceability
To provide consistent and verifiable quality control, our system is fully programmable to execute multiple test phases, varying twist angles and velocities, and complete duty cycle sessions. Operational data for every individual torsion bar is automatically captured and stored against the unique identification marking stamped onto each component, delivering 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 specific customer requirements.
Our micro-percussion marking system is digitally controlled, configured to meet specific customer requirements.
An Integrated UK Manufacturing Solution
With global supply chains facing ongoing challenges, securing heavy engineering components through an integrated domestic route is a priority for industrial sectors. From initial raw material forging right through to the final permanent set, Brooks Forgings provides a resilient, fast, and fully traceable manufacturing alternative.
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.
