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For improved efficiency and better working conditions, the forge suites are arranged and continuously developed to enhance work flow.
Automatic loading feeds a regular supply of steel stock to the induction heaters that deliver billets to the forge at the precise temperature needed for any given component.
Customers are increasingly specifying precision forged components to reduce or eliminate subsequent machining.
Quality is maintained by the application of capable processes confirmed at the point of manufacture.
Care is taken to protect the parts throughout the process.
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Precision sawn steel billets are fed into induction heaters that heat the steel to the exact forging temperature.
Stokes Forgings has forge presses ranging from 500 to 2500 tonne capacity producing a wide range of component shapes and sizes.
The 2500 tonne presses handle components of up to 13kg. The process has been refined to optimise workflow, reduce operator effort and improve consistency.
Complex or large shapes up to 30kg are made on a range of double-acting pneumatic forging hammers with capacities up to 11,000 KgM.
Mid range diesel engine connecting rods, radius arms and wishbones are produced in individual work-cells created to meet the precise needs of customers.
Parts such as radius arms for Land Rover are produced using a multi stage process.
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Precision flash-less forging techniques are used for components such as hubs and gear pinions, improving quality and eliminating waste.
Such precision forged components are close toleranced without draft angles, and therefore require only minimal machining.
2000 tonne precision forging presses are loaded with the exact weight of billet before pressing the steel into the component die.
Leading edge tooling technology, combined with precision feedstock enables 100% material yield to be achieved.
Stokes Forgings believes that ongoing development of the forging process forms a fundamental part of the drive to remove waste and reduce cost.
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An increasing number of components are air cooled after forging. Over the last decade we have worked with customers and
steel suppliers to develop the process. We use the latest air cooling steels to attain specified material properties in a
more cost effective manner.
Some products specify traditional heat treatment operations and we have strategic links with a number of specialists in
the local area to offer the full range of heat treatment facilities if required.
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Tumble and hanging shot-blast facilities are available, matched to the size and complexity of the component, together with a range of painting options.
If required, parts may be cold-coined, hardness checked or magnetic particle inspected on a sample or 100% basis.
A range of machining facilities are available, principally to eliminate customers first machining operations.
Other operations such as painting or shot peening are subcontracted to local specialists.
Some suspension components such as these rear upper control arms are painted, drilled, and bushed.
The integrity of the finished assembly is confirmed via bar code scanning of both the incoming components and the outgoing pallet.
This assembly is supplied line-side, direct to Ford and Jaguar car assembly plants.
Such post forging processes are all part of the Stokes Forgings quality service, and make them the supplier of choice to world class customers.
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To survive in todays increasingly competitive global marketplace, manufacturing companies must be committed to technical excellence, focused on continuous improvement and passionate about delivering customer service.
Our engineers use leading integrated systems to meet customers needs by creating innovative forging solutions.
Integrated through high speed e-networks, Stokes Forgings DELCAM Software is linked with customers own design and process software, enabling parts to be concurrently designed, developed and modelled in real time.
The software is directly linked to Die Manufacturing Facilities where high speed milling, turning and CMM inspection ensure both high precision and repeatability of forge dies.
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The "Plexus" information system, a computer database that was developed by the Stokes Forgings Systems team and Plexus Systems personnel, integrates all aspects of the organisation.
It provides a Shop Floor Control System, Business Operating System, Quality Operating System and Communication System. Plexus creates an overall structure for controlling and monitoring daily operations, and provides an environment for continuous improvement.
Upon receipt at one of the Stokes plants, each bin of steel stock is given a unique bar-coded label that tracks its route, through to the finished component, delivered to the customer.
Every step in the manufacturing process, every location and every bin is bar-coded, scanned and automatically updated.
This ensures total trace ability and also allows Stokes Forgings and its partners to minimise inventory in the supply chain.
Being linked through the Internet, the progress of every job can therefore be viewed and monitored remotely by Stokes personnel, suppliers and customers
The whole system is also linked to the design specifications so customer requirements and design data can be accessed by everyone involved in the component design, manufacture, finishing and delivery. Design changes can be made easily and new developments effectively integrated into the process control at minimal cost.
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