Pull Rod for Tractor Brake Application

Material : S45C Wire diameter : 23.10mm Machine : 4 Stage Bolt former and 100 Ton Hydraulic Press with a 15kW induction heating unit (warm forging) Previous process - Completely machined from square bar stock of 25.0×25.0mm. - Input weight was 850 grams for a finished part weight of 250 grams. - Later hot forging route was adapted with input weight of 600 grams and the slot of 13.0×30.0 milled from a solid forged stock on vertical machining centre. - Customer demand of 1000 parts per day catered by 8 suppliers leading to traceability problems. Improved process - Combination of cold forging and warm extrusion used. - Part forged to a predetermined shape on a 4 stage bolt-former. - The 13.0×30.0mm slot is warm forged to near net shape with a very minimum stock for milling and finishing. - Input weight drastically reduced to 300 grams thus increasing the yield on raw material. - Eliminated the need of expensive vertical CNC machining centre by using an ordinary milling machines. - Customer demand of 1000 parts per day easily met from a single source.