Brooks Expand Product Development & Tooling Design Services

Brooks Forgings Ltd is a diverse manufacturing company specialising in the Hot Forging, Machining and Fabrication of metal components.

We have prepared this article to inform potential customers of the numerous processes that a single component can travel through during its production life.

The recent addition of a 3D printer and the latest QForm forging simulation software, working in unity with existing SolidWorks software, has the potential to transform the way the company does business in the early stages of product development.

Please contact our team today for more information.


1. 3D Design

solidworks logo 3d design

Solidworks is industry-leading 3D design software that provides part, assembly, and drawing capabilities with the added benefits of stress analysis, cost estimation, rendering and animation.

Brooks Forgings currently has 3 seats enabling 3 fully trained design engineers to use the software at one time.

Typically, when a client approaches Brooks Forgings with a viable component for manufacture, they can only provide a worn physical sample or obsolete drawings. The first step in production is to take all of the available information and create a new scaled model in Solidworks. Once generated it enables the creation of detailed digital 2D drawings, 3D renders and can even be exported in a format for 3D printing.


2. 3D Printing – Additive Manufacturing

3D printing enables the low-cost production of prototype parts with incredible accuracy.

A physical and dimensionally accurate component can be 3D printed and handed to the client, giving them the ability to finish machine and even implement into a sub-assembly for final suitability testing.

3d printing shackle prototype in forging industry

The benefits of this capability are particularly evident in the early stage of production. Forging is an industry with high outlay costs and production of tooling and purchase of raw materials often reaches in excess of £20,000. 3D printing can assist in avoiding costly mistakes caused by the production of incorrect dies and ultimately scrap material.


3. Stress Analysis

Various types of Stress Analysis are incorporated into the latest Solidworks package, enabling Brooks Forgings engineers to carry out simulation on either individual parts or assemblies by using finite element analysis. This process can improve and validate performance and reduce the need for costly prototypes or revisions later on in the project.

stress analysis of drop forged shackle

This also enables us to evaluate product structure and design suitability and make alterations to suit various requirements. We can also input various material properties making the system fully customisable


qform forging simulation4. QForm Forging Simulation

QForm is forging simulation software that enables the development and optimisation of tooling and accurately simulates and analyses the forging process.

Why is this so important? It is possible to identify flaws such as inadequate impression filling, laps or folds, and flow-through defects.

Further optimisation of the process can be achieved by varying starting material diameter, forging forces and analysis of die tooling stresses to improve durability and longevity.

qform forging simulation software drop forged shackle

The combination of 3D printing and QForm enables Brooks Forgings to improve lead times and the overall efficiency of the manufacturing process by eliminating forging defects and final application suitability issues before final production tooling and samples are physically produced.

drop forging die displacement analysis in qform

drop forging die effective stress analysis


tooling production simulation cutting paths

5. Die Cutting & Sinking

We have an extensive on-site tooling room that provides complete control and flexibility throughout production. Our machining department plays a key role, enabling a quick turnaround of forging dies when required.

This process is combined with the latest CAM software that gives us the ability to run die cutting simulation to identify potential errors in final tooling production. Tooling is a crucial part of the overall manufacturing process and is the most costly.



6. Drop Forging

The Drop Forging process is just one of many offered by Brooks Forgings Ltd. The shackle in this case study was manufactured using our Banning GOA 1250 drop hammer. Our forging processes utilise induction heaters that are automated with automatic hopper feeds. This supplies the operator with a constant and controlled supply of billets at optimal forging temperature.

drop forging shackle blanks


7. Machining

We currently have 13 CNC machines enabling us to finish machine components as batches come off the forging production line. For the machining of the drop forged shackles in this case study, special quick release jigs were designed and made by our tool room. Two sets of jigs were used, one that allows the facing of the shackle ends and the other to drill the final pin hole.

drop forged shackle machining jigs

Video

3D Printing Timelapse - Additive Manufacturing

3D printing enables the low-cost production of prototype parts with incredible accuracy.

The recent addition of a 3D printer and the latest QForm forging simulation software, working in unity with existing SolidWorks software, has the potential to transform the way the company does business in the early stages of product development.

A physical and dimensionally accurate component can be 3D printed and handed to the client, giving them the ability to finish machine and even implement into a sub-assembly for final suitability testing.

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Request a Quotation

Email: enquiries@brooksforgings.co.uk
  • Tel: +44 (0)1384 563356
  • Fax: +44 (0)1384 563357
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