SUN FORGE - CLOSED-DIE FORGING FOR BEARING RACES, AUTOMOTIVE COMPONENTS, RING JOINT GASKETS, FLANGES, AUTO RINGS, GEAR BLANKS, STEEL BUSHES AND ROLLED RINGS

Sun Forge is a fully equipped advanced forging company that supplies engineered products and services for bearing races and automotive components. Sun Forge manufactures and supplies closed-die forging for bearing races, automotive components, ring joint gaskets, flanges, auto rings, gear blanks, steel bushes and rolled rings.

Established in 1994, Sun Forge is a DIN EN ISO: 9001:2000 TUV Rheinland certified company. Sun Forge has an annual production capacity of 4,000M.T. The forged product ranges from 30mm to 400mm in diameter and from 0.250kg to 50kg. Sun Forge supplies finished products that may be enhanced by forging, spherodised annealing, normalising, CNC turning and heat treatment.

AUTOMOTIVE COMPONENTS

Sun Forge manufactures various types of bushes, gear blanks and rolled rings for the automotive industry. Sun Forge uses 20MnCr5, 16 MnCr5, 42CrMo4, C35 / EN 8 / EN 19, SAE 8620, SCM 420, AISI 1025 and MS grades of raw materials to manufacture automotive and other components.

BEARING RACES

Sun Forge manufactures bearing races for ball, taper, spherical and various types of special purpose bearings. The materials used for bearing races include steel SAE 52100 and 100 Cr6.

EARTHMOVING EQUIPMENT COMPONENTS

Sun Forge manufactures seal rings and pressure rings for earthmovers. We can also manufacture pressure rings for other applications.

PIPE FITTINGS AND METAL GASKETS

Sun Forge manufactures many things for the pipe fitting industry including: metal gaskets, ring joint gaskets, spiral-wound gaskets, rolled SS rings and flanges.

The ring joint gaskets are precision manufactured, metal ring joints used in high pressure applications. The spiral-wound gaskets and rolled rings manufactured by Sun Forge are designed for high pressure, high temperature applications.

The materials used include SS 321, SS 316, SS 316L, SS 304, SS 304L, AISI 1006 and ASTM A105.

PLANT AND PROCESS

Sun Forge is equipped with a state-of-the-art, modern production line for the ring rolling process. The raw material is heated in an induction bar heater and in precisely temperature-controlled furnaces, which provide scale free heating. The plant is equipped with gas cutting and hacksaw machines and modern shearing machines for raw material cutting. The plant uses pneumatic, mechanical and hydraulic power presses for forging.

SPHERODISE ANNEALING

Spherodise annealing and normalising improves the machinability of the annealed hypereutectoid steel and improves its microstructure. To accomplish spherodise annealing and normalising, Sun Forge uses one electrically heated furnace with a capacity of 6,000kg and two oil fired furnaces with capacities of 3,500kg to 4,000kg. The spherodise annealing and normalising process provides improved ductility, removal of residual stresses, improved machinability and grain refinement.

CNC AND CONVECTIONAL TURNING

Sun Forge uses advanced CNC turning machines to provide quality CNC machining services. The CNC, SPM and convectional turning machines are used for centreless, cylindrical and round operations. SPM type convectional turning machines are also used for proof turning and some other special operations. Sun Forge uses PLC and hydraulic type convectional machining centres for various operations.

HEAT TREATMENT

Sun Forge offers heat treatment process works that include:

• Liquid carburising processes
• Gas carburising processes
• Continue hardening processes
• Natural salt bath processes
• Mar quenching processes

FORGING

Forging is a metal forming process used to produce large quantities of identical parts for the automobile and other industries. It improves grain refinement in steel. The process consists of:

• Raw material heating
• Ring rolling process
• Forging

SUN FORGE (P) LTD

We will be enhancing our production capacity at our new plant (about 5,000Mt annually). The new plant is expected to begin production in February 2006. The estimated investment is around one million US dollars and covers an area of 18,290yd². Products range from 50mm up to 500mm in diameter and weigh up to 50kg.

The main plant facilities include an induction bar heater, a mechanical and pneumatic type semi automatic press for capacities of 50Mt to 400Mt, an electrically heated spherodised annealing and normalising furnace (capacity 6Mt) and a CNC turning machine. We also have a fully equipped wet type laboratory equipped with a hardness tester, an Olympus microscope and an electromagnetic crack detector.