Custom Steel Forging.

Global Supplier of Custom Forged Steel Parts

At Donlouco we have been manufacturing and supplying custom-forged steel parts and components to OEMs for over 15 years.

Extensive experience in the manufacture of complex forgings, rod ends, cylinder bases and others. Multi-stage forging tool sets for high forging ratio parts, 1:6.5. Open hammer forging of large parts. High-grade steel manufactured to the highest possible standards and to exact customer requirements. Parts can be heat treated to customer requirements, all parts shot blasted to clean cosmetic standards.

We supply parts to the automotive, machinery, construction and material handling industries. We ensure that our forgings are always the best quality from approved suppliers who use raw materials you can trust.

Forging Specs

Donlouco has extensive experience in forging hydraulic components. Multi-stage forging tool sets for high forging ratio parts, 1:6.5. Cylinder bases, flanged components and rod eye. Part weights from 0.5 kg to 50 Kg for die forging.

Open hammer forging for larger parts. CNC machine capacity 400 Ton approx.

Learn more about the hydraulic cylinder parts we supply.

Custom Forged Parts.

Forging Capacity for Small and Large Parts

Donlouco has the forging capability to manufacture small detailed parts to large heavy forgings.

Maximum forging capacity of 1600 Tons for small parts. Open hammer forging capacity for larger forgings. Forged parts can be secondary CNC Machined to the finished part level.

Tooling for Forged Parts

Donlouco manages the process of designing and production engineering of tools that are necessary to manufacture parts or components. Multi-stage forging tool sets for high forging ratio parts including trim tools etc.

Parts can be reverse engineered and Donlouco has the capability to create 3D models and drawings for all types of forged parts. Primary engineering data is then used to make exact tools for parts and CNC machine programs for the final machining of parts. Tools and processes can be customised to suit customer requirements.

Quality Raw Materials and Steel Grades

All steel grades to meet customer requirements and European standards.

Heat treatment capabilities are also available. Parts can be tested for hardness, impact testing and load testing. Test strategies can be designed to suit customer requirements.

Quality Control and Testing Capacity

Forged parts can be fully tested, tensile, impact, etc at the approval stage and by sampling as required.

All parts are shipped with full traceability records for dimensions and performance tests if required including mill certs for raw materials.

forgings for hydraulic cylinders.

Forgings with Secondary Machining

Donlouco has extensive experience in forging Hydraulic Cylinder Components.

Trusted supplier of forged steel parts with secondary CNC Machining to customers in Ireland, UK, and Europe.

Cylinder Bases, Flanged Components, Forged Cylinder Rod Ends, Forged and Machined Hydraulic Cylinder Trunnions, Forged Hydraulic Cylinder Clevis.

Part weights from 0.5 kg to 50 kg, die forging. Open hammer for large parts.

Max forging capacity: 1,600 Tons (Die).

Steel Forging Manufacturing Process.

In general, the parts that Donlouco manufacture are made from steel. There are multiple steps involved in the forging process to manufacture steel parts, which include the following:

Raw Material Cutting:

The required length of the steel material is cut from stock material or custom blank depending on the part. 

Heating workpiece:

The workpiece is heated normally to white heat, when heated the malleability of the steel blank increases. This allows the workpiece to be shaped to the desired shape where the grain structure is modified to improve the performance of the finished part.

The part blank can be preheated in a furnace and finally heated by an induction heater to the required forging temperature.

Positioning the workpiece:

Once the material is heated to the required temperature, the blank can be forged through a series of individual tools or stepped through multi stages on a single tool depending on the complexity of the part.

Pre-shaping can also be done through mini rolling stations or hammer process. Most forging stages are controlled manually but larger high-volume parts can be automated.

Parts are finally trimmed to remove excess material and to control the final outline of the part.

Shaping and Forming:

The workpiece is formed by a tool that has a top and bottom side. The tools consist of two halves with an impression of the finished part on each side.

Closed Die Drop Forging:

For very complex shapes multiple tools may be used to make the finished part, the process is known as closed die forging. Closed die forging is a metal forming process where the workpiece is inserted into a die and then hammered until it has been formed into the required shape.

This method of forging can be considered a high precision manufacturing process, enhancing the material properties of the final piece.

Forging results in an excellent grain structure in the steel material which is the key attribute to improving the strength and toughness.

Secondary Finishing For Forged Parts.

Depending on the requirements of the parts, forgings can be subjected to secondary finishing operations before the parts are ready for the customer. This could include Heat treatment, secondary machining, dipping, sand/shot blasting to create the desired surface finish.

Secondary CNC Machining

Donlouco has the capabilities to finish forged steel parts with CNC Machining processes such as milling and drilling.

Dipping

This involves dipping the parts into an oil or chemical solution to prevent rusting of the parts or corrosion. Normally a temporary process to protect parts in transit or between locations.

Sand Blasting

This is whereby sand is used in a high-speed airflow to blast away or clean the surface of parts. Basically taking the surface down to the base metal.

Shot Blasting

This is whereby shot or steel balls are used in a high-speed airflow to blast away or clean the surface of parts. Basically taking the surface down to the base metal. The process is manual and is extremely aggressive. Both processes are carried out in a controlled environment ideally in a sealed cabinet or if not possible the operator is wearing protective clothing with breathing apparatus.

Cost-Effective Manufacturing For High-Quality Parts.

Forging Is A Highly Cost-Effective Manufacturing Process For parts

Donlouco Ireland Ltd are experts in achieving cost savings for parts and components,

Forging has a considerable cost advantage over other manufacturing processes, particularly when high volumes are being produced over the longer term.

Forging is the go-to method to manufacture very tough and strong parts and uses less material than other methods. Generally, any secondary operations required such as machining and surface finishing are kept at a minimum, which contributes to cost-effectiveness.