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Successful Cases of
Forged Hubs and Spindles
When purchasing hubs and spindles, product integrity is critical, since it is often what makes or breaks a part in the field. Machined castings or hot rolled machined bars often have poor structural integrity or inclusions that lead to problems with cracking and part failure. As shown in the cases below, forging has proved to be a successful solution to these problems.

Product/Application:
Previous Processing Problems:

Hub for air compressor

Material:

Stainless Steel 		The previous process involved casting, followed by intricate machining.
  • Critical surface quality requirements were not met with the casting.
  • After extensive machining, part rejections arose due to porosity, extending lead times and incurring additional rework or replacement costs.
Forging as the Solution:
Forging as the Solution
  • Forging has successfully replaced casting, providing outstanding strength, soundness and structural integrity properties.
  • Surface quality standards were met through combining the forging process with controlled material selection.
Product/Application:
Previous Processing Problems:

Coupling hub for high pressure cylinder requiring strength and property uniformity

Material:

Alloy Steel

Hub Size:

4-1/4" O.D. X 4-1/4" Long,
Stepped Down to 1-3/4" O.D.
X 5" Long 		The former process involved sawing and machining a hot rolled bar to shape.
  • The longitudinal grain flow caused cracking, which led to field failures.
  • Abuse in the field was causing more wear than expected, resulting in breakage and the need for stronger parts.
Forging as the Solution:
  • A customized, triaxial forging process provided the solution.
  • Triaxial forging produces a special isotropic grain flow, which was required to meet the design specifications.
  • Controlling the grain flow has increased part strength and minimized field failures.
Product/Application:
Previous Processing Problems:

Gearbox pinion

Material:

Alloy Steel 		Previously the pinion was manufactured from a hot rolled bar machined to size.
Machined Bar
  • Cleanliness was critical, but often-times unacceptable inclusions were found on the machined surface, causing rejections.
  • The inclusions often were not found until after finish machining, resulting in excessive time and costs spent repairing the parts.
Forging as the Solution:
Forged Spindle
  • The machined hot rolled bar has been replaced by a forged spindle using 37% less material.
  • Material cleanliness is optimized by controlling melt practices and teaming processes.
  • Material rejections due to inclusions have been eliminated.
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