Guide to the Manufacturing Process

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last updated：Feb 07, 2023

チャレンジフォージ

Official site

From design to shipping! A comprehensive introduction to the manufacturing process!

Here is an introduction to the manufacturing process of Challenge Forge. STEP 1. Design: Quick response in-house to meet customer requests. STEP 2. Steel Storage: High-quality storage of various types and sizes in a covered steel yard. STEP 3. Steel Cutting: Cutting just before forging to prevent contamination with different materials. STEP 4. Steel Heating: Temperature management around 1200°C in an electrically controlled furnace to prevent decarburization. STEP 5. Die Forging: Proud of the high skills of veteran craftsmen and high productivity with multiple pieces. STEP 6. Burr Removal: Removing excess material from forged products and finishing the products. STEP 7. Heat Treatment: Heat treatment at partner factories to standardize the structure and achieve specified hardness. STEP 8. Shot Blasting: Cleaning the surface of products with iron powder to prepare for further processing. STEP 9. Cold Forging: Preparing the processing reference surface for subsequent processes to deliver uniform products. STEP 10. Appearance Inspection: Final dimensional inspection of products completed through multiple processes. STEP 11. Dimensional Inspection: Proud of the high skills of veteran craftsmen and high productivity with multiple pieces. STEP 12. Shipping *For more details, please download the PDF or feel free to contact us.

Related Link - https://challengeforge.co.jp/01guide/flow.html

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basic information

<Main Equipment> 〇1/3t Hammer Line Steel Cutting Equipment: Billet Shear (Mori Iron Works) Steel Heating Equipment: Induction Heating Device (Uchino) 250kw Hot Forging Equipment: Air Drop Hammer (NSC) 1/3t Trimming Equipment: Crank Press (Amada) 45t 〇1t Hammer Line Steel Cutting Equipment: Billet Shear (Mori Iron Works) - Steel Heating Equipment: Induction Heating Device (Uchino) 400kw Hot Forging Equipment: Air Drop Hammer (NSC) 1t Trimming Equipment: Crank Press (Amada) 60t 〇1t Hammer Line Steel Cutting Equipment: Billet Shear (Mori Iron Works) - Steel Heating Equipment: Induction Heating Device (Uchino) 400kw Hot Forging Equipment: Air Drop Hammer (NSC) 1t Trimming Equipment: Crank Press (Amada) 60t 〇Post-Processing Equipment Cold Forging Equipment: Crank Press (Amada) 80t : Crank Press (Amada) 150t Surface Treatment Equipment: Shot Blast (Sakae Casting) Measuring Device: 3D Measuring Device (Keyence)

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Applications/Examples of results

Automotive parts, industrial machinery parts, power tool parts, construction machinery parts, etc. *For more details, please download the PDF or feel free to contact us.

Detailed information

Manufacturing Process: Design We respond quickly in-house to meet our customers' requests.
Manufacturing process: Copper base storage and cutting High-quality storage in a covered steel yard by type and size. Cutting is performed just before forging to prevent contamination with different materials.
Manufacturing process: Heating of copper material Temperature is managed around 1200°C in an electrically controlled furnace to prevent decarburization.
Manufacturing process: Die forging We take pride in the high skill of our veteran craftsmen and the high productivity of our mass production.
Manufacturing process: Deburring Excess material from the forged product is removed, and finishing of the product is carried out.
Manufacturing process: Heat treatment and shot blasting. Heat treatment is carried out at partner factories to standardize the structure and achieve the specified hardness. We clean the surface of products with iron powder to prepare them for further processing.
Manufacturing process: Cold forging We will prepare the machining reference surfaces in the subsequent process to deliver uniform products.
Manufacturing Process: Appearance Inspection and Dimensional Inspection We conduct the final dimensional inspection of products completed through multiple processes. We take pride in the high skills of our veteran craftsmen and the high productivity of our mass production.
Manufacturing Process: Shipment We will safely deliver reliable products to our customers.