Forging
Your specialist for precision forged parts
Precision forged parts are forged parts where very narrow tolerance can be achieved by following the forging process permanently. Our processes enable forging with the +/- 0.1mm tolerance. We are specialized in the production of precision forged parts weighing between 0.001kg and 1kg made of different material. The advantage of precision forged parts is that they can be used mostly in different compounds and without additional mechanical machining. Hot die drop forging is the method in our company – sticks are heated and inserted into the appropriate forging tool.After the forging process, we trim and pierce the semi-finished products to meet many shapes and other requirements. We shape stainless, alloy and carbon steels. In most cases, more complex and larger forgings are further machined.Due to the specificity of precision forgings, we provide the minimum necessary additional machining and thus reduce the machining times. After mechanical treatment,replica watches the products can be further smoothed by the vibrafinish process. If necessary, the products are thermally treated and the desired surface protection is performed (treatment “Magni”, electrolytic galvanic protection, KTL surface protection)
With modern forging lines to fast production
Our production plant boasts 12 modern forging lines providing customers world-wide. We can be proud of fast respond, as the production time from the order to the prototype realisation begins with six weeks.Our forged parts are present in most industrial branches – automotive industry, agriculture, civil engineering, nautics, military industry. Our parts in the automotive industry are in engine parts, safety elements and bodywork parts.
Machining of forged parts
Automated machining of forged parts on technologically advanced machines
The advantage of the Marovt company is that forged parts are machined in our own forge. This is why we are able to ensure forged parts with characteristics defined together. The machining of forged parts is mostly automated; therefore, the human factor is decreased and permanently the same technological process can assure all parts to be machined in the same way and being controlled and tested according to the same procedures.The machining of forged parts is carried out on technologically advanced 3 and 4-axe machines. Our machining centres have the possibility of using up to 40 changeable cutting tools. The tool can be up to 300 mm long and up to 10 kg heavy.The machining center spindle can rotate up to 20,000 rpm. Changing the cutting tool at our centers only takes 1.7 s, which greatly shortens the machining time. All our machining centers have a pallet system that eliminates the time of mounting the forging parts into the clamping device. This increases the efficiency of the machine.The tendency of machining of forged parts is that the machining is done in one grip. This increases the stability of the machining process.Machining of forged parts at Marovt has a long tradition. We can offer you a complete service. Our customers are mainly large car companies, which can guarantee that the company Marovt works well and above all quality. We have experience in machining of forged parts in all metals. The vast majority of our products are made of stainless steel.Forgings parts are also processed by turning on three automated lines.
Production of turning parts
We are experienced in the production of parts made of different material. The majority is made of stainless steel. Moreover, we manufacture products made of hardened material of 64 Hrc.The manufacture is carried out on three different types of turning machines:
- Classic turning machines (14 machines). Turning machines are of different sizes and different complexity. The machining is carried out by using sticks of different diameter with automatic feed. Products with diameter up to 64 mm from sticks or 165 mm from pieces can be machined. The length of the machined part can reach 118 mm. The most technologically advanced lathe can machine with two spindles and three turning machines, which can move in three axes and can carry 12 tools each, for a total of 36 tools. All tools can be driven. Driven tools can produce up to 40 Nm of torque. All tools are controlled by a tool monitor, which ensures timely replacement of the cutting tool and minimizes deviation. Temperature compensation is the key to greater process stability. The main spindle rotates up to 4000 turns.
- Vertical CNC turning machines (3 machines), intended for bulky machining. The diameter of machined parts can reach up to 200 mm and up to 200 mm length. The turning machine can bear 12 tools. Of these, 6 may be driven. The main spindle produces 18 kW and can rotate up to 4500 rpm. The driven tool reaches up to 15Nm of torque and can rotate up to 6000rpm. The stable base and reliable machine construction enable machining of the pieces in precision within +/- 0.005 mm.
- Long turning machines (Swiss type) (8 machines). Machines are intended for long thin products and are mostly used for the production of beams made of different material. The reached shaft tolerance is up to H7. The workpiece diameter can reach up to 32mm and lengths up to 320mm. Linear positioned tools are a guarantee for extremely fast tool change. Under optimal circumstances up to 40 tools can be inserted into the machine. The spindles can rotate at 8000 rpm. One spindle produces 7.5kW of power while the driven tools produce 1kW of power.
Our turning parts follow you everywhere you go
They are used in the automotive industry. Every time you go on vacation, a piece of Marovt company will be with you, either holding the tow hook of your trailer or a bicycle rack. Our shafts are components of a cooling system that keeps your engine running. Even in an accident, our drawbar eyes will make sure that your car is as secure as possible.With our fleet of machinery, we can fulfill your every wish, whether it be pieces with a narrow tolerance field or general construction pieces. Product sizes can range from minimum to 200mm in diameter. The products are made of rod material; however, we have the possibility of processing before the workpieces or forged parts.Products requiring heat treatment are turned with a CBN tool. Turning with a CBN tool saves you from grinding. For this operation, we maintain a tolerance of + 0.004 / -0.003 mm as standard.All our products are subject to the prescribed control procedures. We perform all the measurements in our company. We have the capacity to control the dimensions as well as complete contours.
Materials
Only high-quality steel is appropriate for high-quality products which are mostly assembled in the cars of our customers. By using hot forging process, we shape different types of carbon steel, all types of alloy steel and most of the time stainless steel.The Hot forging process and thus the transformation of steels has a number of specific points in its process. We have directed the development of forging into forging stainless steels, as these steels are increasingly present in automotive engines as well as in other segments of the use of forged parts. The advantage of stainless steels is that they are corrosion-resistant, and do not require additional surface protection. Through the hot forging process, we are able to transform both ferritic, martensitic and austenitic stainless steels.
Engineering development
Complete solutions with modern software and highly skilled employees
With knowledge gained in past years we can provide you with a complete solution – from the idea to the final product. We cooperate with customers from the beginning, from the idea and this is how we contribute to faster solutions in the field of implementation of forged parts into the final system.Modern software and highly skilled employees are keys for the good-quality, fast and expert construction of complete tools and compounds.To design and program machines we use Siemens NX and Visi Vero software, which enable us to read and write data in several possible forms:
NX files, Solid Works files, IGES, PARASOLID, STEP, SXF, DWGBy using conversion modules, we can also open and save:CATIA, Pro / E, Inventor and STLTo achieve the shortest possible time from development to final products, we use modern software for simulating forging. We have a QForm product in use, a synonym for forging simulations. With its help, we anticipate the forging process itself already in the development phase, thus preventing subsequent corrections, and related deviations from quality and timing.
Production of prototypes
By using serial tools for the production of prototypes we can save your time
The prototype pieces are the key for the efficient serial production. This is why we pay a lot of intention to all prototype processes as well as all processes before the serial production. This phase is intended for taking down all data and information which are vital for the implementation in the serial production.
Based on the foreseen technology, which is the result of experience and data from the simulation equipment, we produce serial production tools for the production of prototype pieces in our company. Because we use serial tools for prototype production, we do not need additional time and special adjustments to transition to classic serial production. This gives us the advantage of being able to offer serial production within the shortest possible timeframe.
