Key Questions to Ask When Ordering warm forging fabrication

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Navigating the world of steel forging can often seem daunting, especially when it comes to ordering forged products tailored to your specific needs. Our comprehensive guide will break down each step in detail – from your initial concept to the final order – so you can confidently order your next steel forged product. 

1. Understand your requirements 

Understanding your requirements is the first and perhaps the most critical step when ordering forged steel products. This involves clearly defining your project goals and outlining the specifications that the product must meet.

Start by clearly defining what you want to achieve with the forged steel product. Are you looking to enhance strength, durability, or resistance to wear and tear in a specific application? Or, are you interested in achieving a precise shape or size that cannot be obtained through other manufacturing methods? Understanding these goals will guide your decision-making process throughout the ordering journey.

Specifications are the detailed descriptions of what you need in your forged steel product and they include:

• Dimensions

• Material choice 

• Weight 

• Application 

• Quantity 

• Tolerances

• Finishing requirements

If you need support with any of the specifications, your steel forging partner will be able to aid you. For example, at Greg Sewell Forgings we often help our clients with choosing the best material and forging process for their products. 

2. Select a steel forging partner 

After defining your project requirements, the next step is to select a reliable steel forging company that can meet those needs. Below are some things to consider when making your choice. 

Track Record: Look for a company with a proven track record in producing high-quality forged steel products. This often indicates a high level of expertise and reliability. They should be able to provide examples of past work that aligns with your project requirements.

Certifications: These can be a good indicator of a company’s commitment to quality and adherence to industry standards. Look for certifications such as ISO 9001 (Quality Management Systems) or specific certifications related to steel forging. In addition, ensure product testing is done by an independent third party like NATA (National Association of Testing Laboratories). These can provide assurance that the company has robust quality control processes in place.

Experience: The company’s experience is another important factor to consider. A company with a long history in steel forging is likely to have encountered and solved a wide range of challenges, making them better equipped to handle your project.

Capabilities: The company should have the necessary equipment and technical capabilities to meet your project requirements. Ask about their capacity to handle the size, volume, and complexity of your project, and whether they offer any additional services like design assistance, forging heat treatment, or finishing.

Communication and Customer Service: Good communication is critical in any project. The company should be responsive to your inquiries and able to provide clear, detailed information about their processes and capabilities. They should also show a willingness to understand your needs and work with you to meet your project goals.

For more information on how to choose the best company, read our blog on What makes a good steel forging partner?

3. Enquire about cost and lead time

Once you’ve identified a reliable steel forging company, the next step is to obtain a cost estimation and understand the expected lead time. This will ensure there are no surprises later in the project and help you plan accordingly.

Cost estimation usually incorporates material costs, labour costs, tooling costs, additional processes (such as heat treatment, machining, or finishing), overhead costs, and shipping costs. The steel forging company will supply you with a final figure made up from these components. 

Lead time, on the other hand, is made up of three components: 

• Manufacturing Time:

  This includes the time it takes to prepare the materials, manufacture the dies (if needed), run the forging process, and complete any additional processes such as heat treatment or machining.

• Inspection and Packing Time:

  After manufacturing, the parts need to be inspected for quality and packed for shipping, which can add to the lead time.

• Shipping Time:

  The time it takes to ship the parts from the forging company to your location should also be factored into the lead time.

4. Provide drawing or sample 

The first step in the design phase is to provide the design team with technical drawings, specifications, or prototypes of the steel product you want to forge. This should include all the details you’ve defined in your project requirements, including dimensions, material type, tolerances, and any special features or requirements.

The design and engineering team at a steel forging company are experts in their field. They understand the intricacies of the forging process, how different materials behave under forging conditions, and how to optimise designs for manufacturability. Take advantage of this expertise by seeking their advice and feedback on your design.

In addition, the team can also help you modify your design to better suit the forging process. This could involve changes like adding draft angles to make part removal from the die easier, adjusting dimensions to ensure even material flow, or altering features to reduce the need for complex tooling. These changes can improve the quality of the final product, increase production speed, and reduce costs. 

5. Receive sample confirmation 

Before proceeding to full-scale production, it’s common to produce a small batch of samples for testing. This allows you to verify that the forged parts meet your specifications and have the required physical and mechanical properties. Sample testing can involve a variety of checks, including dimensional checks, visual inspection, and destructive and non-destructive testing.

Once the samples have been tested and meet all specifications and quality requirements, you should receive sample confirmation from the forging company. This is your opportunity to examine the sample parts closely and confirm that they meet your expectations in terms of dimensions, weight, material, surface finish, and other key features. 

If any issues are identified during sample testing or inspection, it’s crucial to communicate these to the forging company promptly. They can then adjust the forging process or die design as needed and produce new samples for testing.

6. Place your order 

To finalise your order, you’ll typically need to sign a formal purchase order with the steel forging company. This document should detail the scope of the project, including the final design specifications, quantity of parts to be forged, material type, delivery dates, and pricing. Before signing, make sure you understand all the terms and conditions and ensure that they align with your previous discussions and agreements.

The purchase order should also include the payment terms. It’s common for steel forging companies to require a deposit before starting production, especially for large or custom orders. The remaining amount is typically due upon completion of the project or at agreed-upon milestones.

Discover Greg Sewell Forgings

At Greg Sewell Forgings, we have 90 years of experience providing Australia with forged steel products. Our experienced and dedicated team works closely with every client to ensure they receive all the support they need during the forging process. From product design to forging testing, we are there to provide an end-to-end service.

Browse our range of manufacturing capabilities and don’t hesitate to contact us if you have any questions regarding our services or quality assurance. Our products comply with national certifications such as AS/NZS ISO 9001 and AS/NZS ISO 14001 and are independently tested by NATA (National Association of Testing Laboratories).

Finding the right metal forging manufacturers is no easy task. Follow our guide to be sure you’ve landed on a great one. 

So you have a metal forging manufacturing project in the pipeline, whether it’s a critical aircraft part, railroad equipment, or hand tools. How do you go about finding the right manufacturing partner for your product or assembly? 

Take your time—and ask the right questions—while choosing the right manufacturing partner, and you’ll avoid aggravation and frustration down the road. Plus, you’ll be rewarded with a partnership that aligns with the specifics of your product or assembly.

Whether you have a one-off project in mind or are looking for a long-term relationship for ongoing production, here are some of the top things to keep in mind while choosing metal forging manufacturers—and the best questions to ask as you’re forging ahead.

For more information, please visit seamless rolled ring forging manufacturer.

Above: Drill bits manufactured by TFG USA via the forging process.

What to Consider When Looking for Metal Forging Manufacturers

The Best Metal Forging Methods for your Project or Product

The different types of metal forging processes are classified by the temperature of the metal being worked with, and range from cold forging to warm forging to hot forging. You’re going to want to ensure the manufacturer you’re considering specializes in the forging method you’re looking for. 

Question to ask your manufacturer: What type of forging is best suited for my metal product, and what are your capabilities in that area?

In-House Metal Forging Manufacturing Capabilities

Look for a manufacturing partner that can handle forging and machining in-house rather than outsourcing key processes. You want a partner that can take care of key production processes from the initial stage to the finished product, as outsourcing can extend lead times, increase cost, and impact quality control.

Question to ask your manufacturer: Which parts of the process are handled in-house, and which are outsourced?

Speedy Turnaround Times for Metal Forging 

Do you need parts by a certain date, or do you have more flexibility? Consider whether the metal forging manufacturer in question offers speedy turnaround times when it comes to everything from preparing quotes to manufacturing products. The ideal manufacturing partner will be able to keep up with demand for ongoing projects.

Questions to ask your manufacturer: What are your delivery options? Is expedited shipping available? Are you able to provide a detailed timeline of each process?

Engineering Acumen in the Forging Industry

The longer the manufacturer has been in the forging industry, the better. Ideally, your manufacturing partner will have engineers with significant experience working in your particular industry, whether it’s automotive, construction, or aerospace. Seek out manufacturers that offer comprehensive testing services, as well. 

Question to ask your manufacturer: What kind of access do clients have to technical experts to answer questions? Do you offer material, hardness, or mechanical testing services? 

Suitable Certification for Custom Metal Forging

Speaking of testing, you will want a provider who has proper certification and who is willing to provide certification details when requested. Preferably, your partner will be ISO-certified. ISO-certified companies are required to follow specific international industrial guidelines and specifications in every process. This assures the client is getting durable and high-quality products. 

Question to ask your manufacturer: Are you ISO certified?

Open Lines of Communication

Communication is essential in any manufacturing project. The best manufacturing partner will provide clear communication lines between supplier and client at every stage of the process. Going through the research process itself will be illuminating—how hard is it to get in touch? How quickly do you get replies? This will likely tell you a lot about how fast you’ll get responses to quotes and inquiries once you’re working together.

Question to ask your manufacturer: What does the order review process look like? 

Proven Track Record in Metal Forging

You’re going to want to find a manufacturer with a long history of producing durable and high-quality forgings, and of producing precise products in terms of measurements and functionality. Check for good reviews from current and past clients. 

Question to ask your manufacturer: Who are some current and past clients I can reach out to for referrals? Does your business have any Google reviews?

Cost-Effective Solutions for Custom Metal Forging

Cost is always a factor, but that doesn’t necessarily mean the cheapest option is the best. You’re going to want a manufacturing partner that will evaluate your specific project and needs and present the most cost-effective solution for excellent results. Often, high-quality products are optimized for long-term performance, which means you might pay more upfront but you’ll save money in the long run. 

Question to ask your manufacturer: What flexible payment and shipping options are available? 

Looking for the Best Metal Forging Manufacturers? 

As your metal parts experts, The Federal Group specializes in metal forging. If you’re interested in forging custom metal parts or components, don’t hesitate to give The Federal Group USA a call. Our experienced support team members will go through your project requirements with you, and help you determine the best course of action. 

Contact us to get started on a free quote for your metal forging project today.

The company is the world’s best seamless rolled ring forging manufacturing supplier. We are your one-stop shop for all needs. Our staff are highly-specialized and will help you find the product you need.