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Hubs & Tooled Forgings

The thousands of in-stock tools at our Franklin Park hammer shop and press plants capabilities provide the ability for us to produce both simple and complex hubs as near-net forgings. During the forging process, material fills the tool or tools and directional grain flow is produced, giving the hub improved strength, ductility, and resistance to impact and fatigue.

Process Highlights

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1. Breaking corners on a hot billet

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2. Initial upsetting of workpiece in hub tool

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3. Flattening to size

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4. Punching the hole in hub

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5. Rolling to sharpen corners

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6. Removing finished part from tool

Infinite Variety of Sizes

Sizes range from 3" to 144" diameter. With no minimums for stocking grades, you can order single-piece or large quantities of products varying from a few pounds to 90,000 lbs.

Cost-Effective

Our practices reduce stock, improve mechanical capabilities and limit additional machining, making it ideal for prototypes and short-run requirements. Working with our technically trained sales staff, we are oftentimes able to provide a more cost-effective solution than a machined bar, weldments, or closed die forgings, all while staying within your specific time constraints.

Why Forged Hubs?

When purchasing hubs and spindles, product integrity is critical often making or breaking a part in the field. Machined castings or hot-rolled machined bars tend to have poor structural integrity or inclusions that lead to problems with cracking and part failure. As shown in the cases below, forging has proven to be a successful solution to these problems.

Product/application

Hub for air compressor

Material

Stainless Steel

Previous processing problems

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

Today the part is made as a forging, providing outstanding strength, soundness and structural integrity properties.

  • Surface quality standards are met through combining the forging process with controlled material selection.
Air compressor

Product/application

Coupling hub for high-pressure cylinder

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

Previous processing problems

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

Today, a customized forging process provided the solution.

  • Forging produces a special isotropic grain flow, which is required to meet the design specifications.
  • Controlling the grain flow has increased part strength and minimized field failures.
Hub

Product/application

Gearbox pinion

Material

Alloy Steel

Gearbox pinion spindle

Previous processing problems

Previously, the pinion was manufactured from a hot-rolled bar, machined to size.

  • 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.
Gearbox pinion spindle

Forging as the solution

Today 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.