Forgings

RÜBIG forgings

Forgings offer a multitude of design possibilities with improved fiber and fabric structure. Besides complicated shapes, production parts can be produced inexpensively as well.

Due to our longstanding experience in this field of business, we go through and execute the design from sketch to the finished drawing and subsequently carry out  reliably the cost effective mass production of drop forgings.  

  • optimized both in form and function
  • economical and flexible
  • 0.01 to 3.00 kg / piece

The existing manufacturing systems of RÜBIG-forging are designed for efficient production and further processing of forged parts. Our manufacturing systems are capable of producing from several hundred parts to more than 100,000 units and we are thus in a position of supplying not only international corporations but also small to medium companies.

Experienced staff and extensive testing facilities ensure a high level of quality.

Results - All out of one hand

Pre-finished forgings with
machining / heat treatment / surface finishing
  • It is nowadays a matter of course to obtain ready to be assembled components from suppliers. As a result of this, we are able to set up our production-line according to increasing demands.
  • At our modern CNC machining and lathes centers, we focus on modern equipment - producing high-quality NC-machined forgings and doing NC machining for our customers as well.
  • Heat treatments, such as normalizing or quenching, are largely done by us in-house. All other treatment methods such as case hardening or (plasma-) nitriding, protective gas hardening, etc. take place at our sister facility Rübig Heat Treatment.
  • Surface finishes, such as copper galvanize, powder coating, "dacromet" coat, etc. are carried out at proven suppliers of us.
  • There are many assemblies where welding operations need to be carried out – this way, casings for forgings are put together.
  • Furthermore, we produce weldments in small or medium series. At this it is beneficial that heat treatment can be done in the same organization. The tension produced during the welding is relieved by the annealing process. In this way, warpage during a following mechanical editing and the danger of crack formation are prevented.
  • In the case of especially high stressed or safety-relevant components, we offer crack tests via magnetic particle testing.

Forged solutions

The design of forgings significantly influences the process and tools to be applied.

In order to not produce a part unnecessarilly expensive, the design of forged parts for existing standards (DIN 7524) norm recommends the cooperation with forgings. We readily take on this task and construct detailed design proposals for precast-drawings, 3D-data design, samples or sketches.

In the RÜBIG forging technology division, forged parts are produced from different grades of steel, such as construction steel, case hardening steel, quenched and tempered steel, etc. Stainless forged parts, such as hunting knives made of Böhler N690, stainless tool steel or Damascus steel are forged in the die. As a forged raw part, these can be either cooled down in a controlled manner after reshaping using the forging heat, or directly tempered. Each individual forging blank will be blasted in our drop forging after cooling or annealing (normalising, or soft annealing). The sand blasting is carried out in a troughed belt machine, which is interlinked with a cleaning drum. In this way, the blasted surface can be smoothed at low cost.

RÜBIG Die Forge

  • Our forge is the center of all operations, the manufacturing equipment is for forgings weighing from 10 grams to 3 kg and are designed up to a length of 400 mm.
  • The selection of materials used for processing, range from simple structural and tempered steels to stainless steels. Also, copper alloys and sheet metal can be processed.
  • We also carry out emboss operations on our drop forges. This can significantly restrict tolerance on the thickness.
  • Further processing of forgings is carried out on eccentric forging-presses exerting pressure forces of up to 230 tons.  Besides trimming and punching holes, it can also carry out bending, riveting or partial calibrations.
  • We gladly offer press-work including the tools for it.
  • Many parts are already ready after forging – particularly due to our ability to work with very limited tolerances, rework can be avoided.
  • By sandblasting, scrubbing and/or tumbling the forgings - depending on the requirement - smooth or polished surfaces can be achived. Stainless steel parts are also stained and passivated.

We also offer machining as job order production in serial processing of milling and turning parts. However, the production in this context does not require the previous hot forming or die forging of the raw parts (i.e. hammer parts), since saw cuts are also processed.

Creativity for the benefit of our customers

Problem-solving

No matter which development stage your parts are in, be it design drawing, draft, sample or test part, in each case we manage the transition to die-forged parts with the help of our expert knowledge. Furthermore, the most reliable and cost effective volume-production is guaranteed by series manufacturing.

Precision

By continuously improving our production methods, tolerances can be achieved which are significantly lower than as set by the norm. This means less rework or the entire elimination of rework by adherence to the required norm.

Further processing methods

With the existing in-house systems, forgings can be machined, welded, pre-assembled, heat-treated or surface-coated. Thus, products reach the customer on request, assembled and ready for installation.

Quality

RÜBIG products are known for their high quality. Our certification according to ISO9001:2008 as well as our safety standards in the manufacturing processes ensure continuous development of our products.

Safety

The safety of RÜBIG products can best be described by some typical examples - like:

  • in racing engines, where forged connecting rods and rocker arms made by RÜBIG withstand extreme stress loads, or
  • on mobile cranes, where a linchpin secures a pulley at the top of crane jibs.

In each case, failure of the parts could be fatal, that's why customers choose the safest and best product on the market - forgings made by RÜBIG.

Technology for the Future


Before a new forged piece may be created, the required tools must be produced. Their production is already an important decisive factor in the possible quality and economic parameters which might be achieved by forging. This is why computer-aided design solutions are always developed in close cooperation with the customer as well as with the tool-making specialist.

The production of new tools is always carried out by means of HSC-milling at RÜBIG’s in-house tool-making workshop. The milling programs required for this purpose are derived directly from the 3D model. This procedure enables exact fabrication of forms which eliminate distortion after the hardening process and prevent the occurrence of transfer errors when engravings are performed. Heat treatment is carried out in a state-of-the-art facility, at the sister company RÜBIG Härtetechnik.

As with all information, tools and forged pieces stay in-house; absolute confidentiality of any new developments is guaranteed.

 

State-of-the-art tool making technology – the prerequisite for flexibility and quality

Applications

Formwork clamp

Clamps made from die forged steel show higher tenacity and consistency in comparison to cast clamps. This makes it possible to design parts lighter, more wear-resistant and nevertheless safer. We deliver these clamps ready to install - the welding and mounting is done at our site.

Parts with straight gearing

Fine sprockets starting from 1mm seperation engage precisely with one another and by this allow a linear adjustability of the components. By the embossing of the forgings finely formations of the sprocket tips as well as restricted tolerances of the components and straightness are achieved. The finishing happens at our CNC-controlled 4-axial machining centers.

Expansion joints

Road bridges have to be accomplished with expansion joints at both ends. In this - not classical at all - case of application, forgings are virtually forming the cobblestones. These are exactly those applications for which we provide our cooperation from the early stage of constructive designing. By doing this, the possibilities of die forging can be used in the best possible way.

Engine components

Conrods, overhead camshafts and tilting lever are classical forgings. Significant for this are the high requirements in quality and speed when assembling new components as well as the possibility to adopt 3D construction data. Heat treatment has also high relevance in this case. In cooperation with our sister company we are able to provide the best possible heat treatment processes.

Tooth lock washer, parts with spur gearing

Tooth lock washers are versatile. Either as weldable standard parts (which we have in stock at any time), or as customer-specific components accomplished with spur geared area, they can be used to realize stable and still easily detachable angle fittings.

 

Constructional steelwork

In many places, clamping plates are used as standart elements to allocate beams. We have improved those clamping plates and therefore significantly enlarged the field of application, increased the clamping force and minimized the weight of the components. Moreover, we forge customers' logos, part numbers, etc into the components at request.

Agricultural engines

Forged plug bolts, zinc mounting, eyebolts, etc. come into operation in this field of industry. The roughest operating conditions require a solid execution and high wear resistancy. 

 

The con rod / connecting rod is a typically produced motor part as a forged component. We also forge these from nitriding steel, wherein a part number is stamped on each forging blank and then the forged part is calibrated for straightness. The stamping is carried out on hydraulic presses, although in series production, the connecting rods are generally produced as impact and not as pressed part. Other typical drop forgings parts are toggle levers, toothed locked washer with spur gearing, bearing bolts, clamps and other shaped moulding blanks. We are fully equipped for the production of the toothing as well as for the turning and CNC milling. In particular, the area of machining technology will continue to expand – currently, there are several NC lathes, CNC milling machines or machining centres available for processing the machine parts that have been produced by die forging. In addition, shafts or blanks with a splined shaft profile or serration profile as well as with helical gearing can be machined.

Products Die Forge
Products of the Die Forge division at a glance: