Auto Parts Forging — Passenger Car, Commercial Vehicle & Two-Wheeler
Shivam Forge manufactures precision hot-forged automobile components for passenger cars, commercial vehicles and two-wheelers from its Shapar, Rajkot facility. Our automotive forging range covers steering knuckles, wheel hubs, axle shafts, connecting rods, crankshaft forgings, brake cams, suspension arms, fork yokes, swing arms and engine components — produced in EN8, EN24, SAE 4140 and SAE 4340 to OEM drawing specifications with IATF 16949-aligned quality controls.
Automotive forgings must meet tighter tolerances, higher fatigue life requirements and more rigorous quality documentation standards than most industrial applications. Every steering knuckle must survive over 10 million steering cycles. Every connecting rod must handle peak combustion loads thousands of times per minute for 200,000+ km engine life. These demands make the forging process — with its refined grain structure, predictable mechanical properties and documented traceability — the only engineering-sound choice for critical automotive chassis and powertrain components.
Front and rear steering knuckles forged from SAE 4140 or EN24 to OEM drawings. Knuckle geometry — kingpin boss, wheel bearing housing bore, brake caliper mounts and tie rod arm — is forged near-net with 3–5 mm machining stock on critical surfaces. Ball joint tapers and wheel bearing bore are finish-machined to H7 tolerance. Used in passenger cars, SUVs, LCVs and light commercial vehicles.
Forged wheel hubs for driven and non-driven axles in passenger car and commercial vehicle applications. Hub flanges, stud hole patterns, bearing seat diameters and pilot diameters are machined to OEM specifications. Brake drum forgings in EN8 and EN9 with machined drum bore, hat section and wheel stud holes. Balancing grades to G6.3 available on finished hubs.
Solid and flanged half shafts for live rear axles forged from EN24 and SAE 4340. Shaft section is induction hardened to 58–62 HRC with core hardness 28–35 HRC for torsional fatigue resistance. Flanged end machined with wheel stud holes and pilot spigot. Splined end cut to SAE or DIN specification for differential engagement.
Forged connecting rods in C70 (fracture-split grade) and EN24 for petrol and diesel engines from 50cc to 12L displacement. Big-end and small-end bores, shank width and centre-to-centre length are machined to drawing. Fracture-split (cracked-cap) connecting rods produced to automotive OEM specification for cylinder block-mounted applications. Weight-matched sets available for balanced engines.
Crankshaft rough forgings for 2- to 6-cylinder engines in EN24, SAE 4140 and SAE 4340. Forging process establishes the crank throw geometry, counterweight positions and journal diameters with machining stock. Heat treatment to Q&T condition prior to delivery to engine machining facility. Fillet rolling on journal-to-web radii available to improve fatigue life by 30–40%.
S-cam brake shaft forgings for air brake systems in commercial vehicles — forged from EN8 or EN24 with cam lobes near-net forged and finish-machined. Suspension arm forgings (A-arms, trailing arms, wishbones) for passenger car and SUV suspension systems in SAE 4140. Camshaft rough forgings for diesel and petrol engines with lobe geometry established by forging before final cam grinding.
Two-wheeler engine crankweb forgings for 50cc to 400cc motorcycle and scooter engines. Crank pin, main bearing journals and flywheel flange are forged in EN8 or EN24 to OEM drawings. Crankweb assembly balance is maintained by precise counterweight forging geometry. Used by domestic two-wheeler OEMs and their Tier-1 suppliers.
Rear swing arm forgings for motorcycles and scooters in SAE 4140 and aluminium alloy alternatives on request. Pivot tube boss, rear axle slot, chain adjuster and suspension linkage mounting points are forged near-net and machined to assembly dimensions. Swing arm forgings offer superior fatigue life vs cast equivalents in high-performance and enduro applications.
Upper and lower fork yoke (triple clamp) forgings for motorcycle front suspension in EN24. Fork leg bores, stem taper and handlebar clamp features are forged to establish the component envelope. Fork leg bores are precision-bored to H7 tolerance for zero-clearance fork assembly. Used across 125cc to 650cc segment motorcycles.
Rear sprocket hub and brake disc mounting hub forgings for motorcycles in EN8. Hub centre bore, wheel stud pattern and sprocket or disc mounting bolt circle diameter are machined after forging. Spline connection to rear axle is cut to SAE specification. Supplied as rough forgings or finished machined components per customer requirement.
Axle shaft, differential case and spider gear forgings for three-wheelers and small commercial vehicles. Differential case forgings in EN9 with ring gear mounting face and bearing bore machined to OEM specification. Spider gear forgings in case-hardening steel (17CrNiMo6 / SAE 8620) with profile ground teeth for smooth differential operation.
Structural two-wheeler component forgings including handlebar stems, footpeg brackets and frame connector plates in EN8 and IS 2062. These safety-critical structural forgings are produced with tighter-than-standard flash control and 100% visual inspection to ensure no fold defects that could initiate fatigue cracks in service.
While our primary certification is ISO 9001:2015, our quality controls for automotive customers align with IATF 16949 requirements: PPAP Level 3 documentation, FMEA-based control plans, MSA for measurement systems, SPC for critical characteristics and annual layout inspection. We are positioned to pursue full IATF 16949 certification as our automotive business grows.
For new automotive forging programmes, we prepare PPAP Level 3 submissions: Part Submission Warrant (PSW), dimensional results on 30-piece initial samples, material test reports, process flow diagram, PFMEA, control plan, MSA results and initial sample inspection report (ISIR). PPAP packages are submitted through customer supplier portals and followed up until formal part approval.
For safety-critical automotive parts — steering knuckles, connecting rods, half shafts — we arrange fatigue testing through accredited external laboratories on first article samples. Metallurgical section examination (grain flow, microstructure, case depth on induction-hardened parts) is performed by our QC team and documented in first-article reports. Charpy impact testing is included for EN24 and SAE 4340 components.
Automotive forgings are marked with part number, heat number, material code, week and year of manufacture and supplier code per OEM marking requirements. For engine components, component-level serial number traceability (data matrix or stamp) is applied. Marking method — ink stamp, paint marking or laser engraving — is confirmed per OEM specification.
Statistical process control (SPC) charts are maintained for critical forging dimensions — flash thickness, overall length, boss diameters — in high-volume automotive production. Cp and Cpk values are calculated and monitored against the minimum 1.33 Cpk requirement for automotive special characteristics. Process adjustments are made proactively when Cpk trends toward the control limit, before non-conforming parts are produced.
We actively support OEM supplier qualification audits, providing factory access, documentation review and process demonstrations to procurement and quality teams from automotive manufacturers and their Tier-1 suppliers. Supplier questionnaires from domestic and international OEMs are completed within 5 working days. Reference letters and case studies from existing automotive customers are available on request under NDA.
Automotive forgings are manufactured to tolerances and quality requirements that push forging process capability harder than almost any other application. A passenger car steering knuckle must be dimensionally accurate enough to assemble without shimming, strong enough to survive a 30g kerb strike impact, and light enough that the unsprung mass target is met — all from a single forged component that costs less than a restaurant meal. Meeting these simultaneous constraints demands a forging process optimised for near-net shape accuracy, material consistency and repeatable mechanical properties. Shivam Forge has been developing and manufacturing automotive forgings from its Shapar, Rajkot facility for over 20 years, and the technical discipline built over those years is embedded in our process controls and tooling design practices.
The automotive product range we manufacture covers the full vehicle structure: chassis components like steering knuckles, wheel hubs and suspension arms; powertrain components including connecting rods, crankshaft rough forgings and camshaft forgings; driveline components like axle shafts, differential cases and spline hubs; and braking components including brake cams and brake drum forgings. Two-wheeler and three-wheeler applications — engine crankwebs, swing arms, fork yokes, sprocket hubs — are also a significant part of our production. The diversity of automotive applications we serve reflects the breadth of process capability at our Rajkot facility rather than superficial product listing.
Material knowledge is critical in automotive forging because the wrong grade in the wrong application is not just a cost issue — it is a safety issue. EN8 is entirely appropriate for brake drum forgings where the loading is primarily compressive and thermal. EN8 in a steering knuckle forging that sees bending fatigue loads is a failure waiting to happen. Our technical team reviews the application, loading mode, operating temperature and section size before confirming a material grade. For new development programmes, we use the customer's existing FEA data or our own process FMEA to verify that the proposed material and heat treatment will meet the fatigue life target.
Quality documentation for automotive customers follows IATF 16949-aligned practices regardless of whether the customer specifically requires IATF certification from us. PPAP Level 3 documentation is prepared for every new part launch: dimensional results on 30-piece initial samples measured on CMM, material test reports linked to the originating billet heat, process flow diagram, PFMEA, control plan identifying all special characteristics, and MSA results for the gauges used to measure critical dimensions. This discipline at the development stage translates into production process stability — parts that make the first article right tend to stay right in volume production.
Automotive supply chain integration is something we take seriously beyond the component itself. We maintain consistent production scheduling so that call-off orders are delivered on the agreed date without excuses. Our internal rejection rate on automotive parts has been below 0.5% for three consecutive years, which matters to Tier-1 suppliers who run tight JIT stock levels. Our account managers communicate proactively when lead times are under pressure, giving customers the advance notice they need to adjust production plans. If you are looking for a technically capable, quality-documented automotive forging supplier in India, call +91 92657 72827 or email sales@shivamforge.com to discuss your programme requirements.
We manufacture a comprehensive range of automotive forgings including steering knuckles, wheel hubs, axle shafts, connecting rods, crankshaft rough forgings, brake cams, S-cam shafts, suspension arms, camshaft forgings and two-wheeler components — engine crankwebs, swing arms, fork yokes, sprocket hubs and brake disc hubs. Both rough forgings and machined finished components are supplied.
Our standard automotive forging materials are EN8 (080M40) for lower-stress structural parts, EN24 (817M40) for chassis and powertrain components requiring high fatigue strength, SAE 4140 (42CrMo4) for steering and suspension parts, and SAE 4340 (36CrNiMo4) for the highest-duty applications including racing driveshafts and heavy-duty axle shafts. C70 fracture-split grade is used for connecting rods requiring cracked-cap assembly.
Yes. We prepare PPAP Level 3 documentation including Part Submission Warrant, dimensional results on initial samples, material test reports, process flow diagram, PFMEA, control plan, MSA results and initial sample inspection report. PPAP packages are prepared for new part launches and submitted through customer supplier portals. First-article approval timelines are agreed with the customer programme manager at kick-off.
Yes. Two-wheeler forging components are a significant part of our production including engine crankwebs, swing arms, fork yokes, sprocket hubs, brake disc hubs and structural bracket forgings. We supply Tier-1 and Tier-2 suppliers to domestic two-wheeler OEMs and produce components for aftermarket and export applications.
Safety-critical automotive forgings receive application-specific heat treatment: steering knuckles and axle shafts undergo quench and tempering (Q&T) to achieve the specified core hardness (typically 28–38 HRC). Spline sections and journal surfaces are induction hardened to 58–62 HRC case hardness. Connecting rods are normalised and stress-relieved. Hardness is verified on every batch and recorded on the inspection certificate.
Yes. Steering knuckle forgings are manufactured to customer OEM drawings. We conduct a die design review before tooling manufacture to ensure forging feasibility, draft angles, flash gutter design and grain flow direction are optimised. First-article dimensional inspection covers all OEM-specified critical characteristics with CMM measurement and a full inspection report submitted for approval.
Yes. In-house induction surface hardening to 58–62 HRC on shaft journals, spline sections and cam lobes is a standard process for automotive components. Hardened depth is controlled to 1–4 mm as specified. Post-hardening low-temperature temper (160–180°C) is applied to reduce brittleness. Hardness traverse testing (sectioning and microhardness measurement) is available for development and qualification samples.
Shivam Forge has over 20 years of experience supplying automotive forgings to Indian Tier-1 and Tier-2 suppliers serving major domestic OEMs in the passenger car, commercial vehicle, tractor and two-wheeler segments. Our Rajkot location is well-positioned to supply automotive clusters in Pune, Chennai, Gurugram and Ahmedabad by road with predictable 1–3 day transit times. References are available on request under NDA.
Why Choose Shivam Forge
Shivam Forge delivers precision hot-forged components from our integrated Shapar, Rajkot facility — covering forging, CNC machining, heat treatment, and quality inspection under one roof.
