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die production alfing mafa kessler

Die production

We drop-forge raw parts with a length between 1.5 and 4.5 m. The forging dies are manufactured on high-precision CNC milling machines. As a result, far fewer machining allowances are required for mechanical production. CNC programs for the production of our dies are created from the 3D model of the forging blank using CAD/CAM interface.

drop forge kessler mafa alfing

Close die forging

With high-precision dies and close-contour forging, we enable a low and efficient machining volume in the subsequent mechanical manufacturing processes. Counterblow hammers with impact energies of 450 or 630 kJ are used for drop forging. The chamber furnaces bring the raw parts to temperatures up to 1300 °C. The raw parts can weigh up to 2.6 t and have a length up to 4.5 m. Several heating processes are required parallel to the forging depending on the operating weight. With drop forging, we achieve optimal continuous grain flow, ensuring high component strength.

press forge alfing kessler mafa

Press forge

Blanks from 4.5 to 9 m in length are forged with hydraulic presses in partial dies in a single-stroke process. Extremely high forming forces have to be mastered here. For stroke-by-stroke forging, the blanks (spindles) are heated in sections to up to 1300 °C. Then the spindle sections are axially upset and the individual connecting rod bearing journals are vertically pressed. This is how the shaped component is created step by step. All devices for single stroke forging are designed and manufactured by the ALFING Kessler machine factory. Due to our high level of process reliability in forging, we can keep the oversize for mechanical machining very low.

heat treatment alfing mafa kessler

Heat treatment

After the actual forging process, the subsequent tempering is decisive for the quality. The raw parts are heated in bogie hearth furnaces to a temperature above the limit for microstructural transformation. The parts are then quenched in oil or water baths and thus hardened. The raw parts are then tempered and slowly cooled in order to give the material the necessary mechanical strength values. This is where the experience and special know-how of the experts at Maschinenfabrik ALFING Kessler come into play.