Forging and Pressing Division specializes in manufacturing of forgings for driveshaft components.
The Division has the facilities to produce a wide range of different forgings. It is equipped with high performance stamping and heat-treatment machinery with broad technological capabilities.

In Forging Division of Belcard JSC they apply complex mechanized production lines, consisting of high-frequency induction heater, crank die-forging press, trimming press and conveyor heat-treatment unit.
The main equipment is crank hot-forging press with the force from 10MN up to 40MN and horizontal forging machines, the force being 8MN and 12.5 MN.
The above mentioned production lines forge the parts as per GOST 7505-89, 4-5 class of accuracy of various shapes and complexity.

The design capacity of Forging and Pressing Division amounts to 35 000 tons per year.

The production of forgings is carried out by hot forging in open dies and landing on horizontal forging machines which makes it possible to produce forgings of various degrees of complexity, with minor deviations in stamping and minimum allowances for machining. This provides significant savings in metal. Stamping of piece is made from billets.

The use of low oxidation induction heating of billets before stamping in comparison with conventional heating in gas furnaces increases heating rate, reduces scaling, improves working conditions and increases productivity.

In order to maintain mass production and use the residual forging heat, heat treatment of forgings on some lines is provided in the furnaces, located in the complex production lines.

In order to save metal and improve metal utilization factor more advanced metal-saving technologies for production of forgings were introduced.

We apply the technology of stamping in split dies, which allows to significantly reduce metal consumption, increase accuracy of forgings and labor productivity.

We have implemented preliminary source billet shaping for subsequent stamping by means of cross-wedge rolling with an automated system included in the production line. This technology is used for forgings with an oblong axis and a significant difference in the areas of cross-sections along the axis (spline yokes). It can also significantly reduce the consumption of metal while producing forgings.

The technique of cross-wedge rolling (CWR) is implemented and widely used in Forging and Pressing Division.

It differs from other processes in high metal utilization factor, the ability of full process automation, maximum fitting of the rolled piece to the part profile, wide technological capabilities, high tool life, low noise level, lack of vibrational oscillation source. In terms of efficiency the technique of hot cross-wedge rolling is superior to stamping on hammers, presses, horizontal forging machines and is second only to cold heading and extrusion operations.

The technique of cross-wedge rolling allows producing all kinds of parts such as bodies of rotation with cylindrical, conical, spherical and other complex surfaces, with various grooves and protrusions.

The technique of cross-wedge rolling can be applied to machine constructional and a number of tool steels, superalloys, titanium, zirconium, copper- and aluminum-based alloys.

In the context of small-batch production the technique of cross-wedge rolling is not profitable due to high tool cost.

At the moment, Forging and Pressing Division of Belcard JSC has the facilities to produce billets with a diameter of 8 to 40 mm and length up to 100 mm by the technique of cross-wedge rolling.

Furnace sector of Forging and Pressing Division of Belcard JSC includes gas ovens for rolled steel heating prior to cutting, highly efficient gas quench-tempering units, chamber electric resistance furnaces, shot-blast units.
The use of synthetic quenching medium in manufacturing reduces heat treatment cost.

To substantially reduce the pre-production time, lower the costs and improve the quality of die tooling, Pro/Engineer end-to-end solid-state design system was introduced.

Highly qualified staff in the field of hot stamping technology development, die tooling designing, as well as developed toolmaking facilities allow developing new products of an appropriate quality level within a very short time period.

Forging and Pressing Division has extensive experience in all types of stamping mentioned above and is interested in receiving orders for its products. We will consider any orders for manufacturing of products of any description and volume at our Forging and Pressing Division.