November 2024 Volume 6

EQUIPMENT & TECHNOLOGY

PIONEERING PRECISION IN A RAPIDLY EVOLVING INDUSTRY Case Study of FIA Member Viking Forge

I n the heart of Northeast Ohio, Viking Forge stands as a leader in the hot forging sector, navigating the fast-paced and highly competitive landscape of modern manufacturing. As global competition intensifies and product life cycles grow shorter, Viking Forge distinguishes itself with advanced technological capabilities that push the science of forging forward. Specializing in precision closed-die forging, Viking Forge leverages state-of-the-art equipment and processes to stay ahead. From PLC controlled systems to quick-change tooling and fully automated production lines, the company consistently delivers high-quality near-net forgings. Their expertise in forming carbon, micro-alloy, and stainless steel—ranging from 1 to 100 pounds—sets them apart, offering competitive pricing while maintaining a superior standard. Serving a diverse range of industries, Viking Forge produces critical components such as gears, wheel hubs, trucking hitch rings, and valve parts, meeting the exacting demands of its customers. The Challenge: Innovating Disc-Brake Manufacturing One of Viking Forge’s recent challenges was navigating the complexi ties of manufacturing disc brakes. The process of transforming a cylindrical billet into a finely-tuned disc-brake requires precision at every stage. From the initial cylindrical form, through flattening into a pancake shape, and finally into a ring-like preform, each step introduces risks (see Figure 1). Stress on the dies and material folding can jeopardize the integrity of the final product, potentially leading to costly defects and downtime.

The Solution: Advanced Forging Technology To overcome these challenges, Viking Forge implemented a cutting edge 3-hit process for a new disc-brake job. At each of the three forming stations, the material progresses from its initial billet form to a flattened pancake, then to a ring shape, and finally into its final disc-brake configuration. This ring shape is a crucial step in mini mizing stress on the dies, preventing premature wear, and main taining the integrity of the part. A key advantage in this process was the use of FORGE by Trans valor, a simulation software that allows Viking Forge to virtually test and refine each stage of production. By simulating the process digitally, they can identify potential issues—like material folding— before physical production begins. Early simulations revealed areas where folds could occur, enabling engineers to adjust the design and avoid costly errors in the real-world manufacturing environ ment (see Figure 2).

Figure 1

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