Integrated Hot Forging + CNC Machining + Heat Treatment at Shapar GIDC, Rajkot
Shivam Forge provides integrated forging and CNC machining services — hot forging, heat treatment, CNC turning, VMC milling, drilling, grinding and surface treatment — all under one roof at our Shapar GIDC facility in Rajkot, Gujarat. We deliver fully machined forgings ready for assembly, achieving IT6/IT7 bore tolerances, Ra 0.4 μm on bearing seats and ±0.02 mm on machined dimensions, with CMM-verified final inspection.
Splitting forging and machining between two suppliers creates three problems: quality accountability gaps when a machining defect traces to a forging dimension, extended lead time from logistics between suppliers, and doubled documentation overhead. Shivam Forge's integrated forging-and-machining service puts hot forging, heat treatment and CNC machining under one quality system, one purchase order and one delivery. The result is faster delivery, lower total cost and a single point of accountability for dimensional compliance from billet to finished machined part.
CNC lathes with turning diameter up to Ø800 mm and 2000 mm between centres. Turning of OD profiles, bore diameters, undercuts, grooves, tapers and thread forms. Tolerances to IT6 on bores and journals. Live tooling available for cross-drilling and milling operations in a single turning setup.
Vertical Machining Centres with 1000×600 mm table, 0.001 mm positioning resolution. Face milling, pocket milling, slot milling, drilling, boring and tapping. Complex 3D profiles machined from STEP/IGES 3D models directly to CNC program via CAM. Particularly suited to flanged forgings, knuckle arms, housing bores and machined pads.
Surface grinding on reciprocating and rotary table surface grinders for flat surfaces to Ra 0.4 μm and flatness ±0.01 mm. Used for sealing faces on valve bodies and flanges, bearing seat end faces and precision locating surfaces on machined forgings. Grinding wheel dressed and verified before each batch.
OD cylindrical grinding to Ra 0.4 μm and IT5/IT6 on journal diameters up to Ø250 mm. ID grinding of bores to Ra 0.8 μm and IT6. Used for bearing seats, precision bush bores, hydraulic cylinder OD and spindle journal diameters where CNC turning alone does not achieve the required surface finish or tolerance.
Radial arm drilling and VMC-based drilling of bolt hole patterns, cross-holes, oil passages and threaded holes in forged components. Boring of large-diameter holes (up to Ø400 mm) to H7 tolerance. Thread tapping from M5 to M64 in carbon steel, alloy steel and stainless steel forgings.
After CNC machining, forgings can be surface treated at our Rajkot facility or at approved subcontractors within 5 km: zinc phosphate (2–5 μm) for corrosion protection of carbon steel automotive forgings, black oxide for aesthetic finish, zinc plating (Cr3 trivalent) and electroless nickel plating for corrosion protection of machined hydraulic and valve components.
Parts begin as hot-forged closed-die forgings produced on our friction screw presses and hammer forging lines. Flash is trimmed to ±0.3 mm. Forging grain flow is oriented to maximise fatigue strength at the critical sections of the machined part — not an afterthought as it is when forging and machining are split between suppliers.
Heat treatment — quench and temper, normalising, gas carburising, induction hardening — is performed in-house before machining. This sequence is mandatory: machining a quenched-and-tempered steel is harder than machining normalised steel, so heat treatment before machining must be specified correctly to avoid work-hardened surfaces that break tools and produce poor surface finish.
Our CNC programmers plan the machining sequence from knowledge of the forging geometry — forging datums, forging skin removal requirements, and the forging dimensional tolerances that the machining process must accommodate. This means the first operation removes forging skin reliably and the machining datums are set from the forging features that best represent the part's design intent.
Finished machined forgings are inspected on our 3-axis CMM (Renishaw TP20 probe, measuring volume 700×500×500 mm). All critical dimensions from the customer drawing are measured and reported as actual vs. nominal with tolerance verdict. CMM dimensional report is issued with every production batch.
Surface finish on bearing seats and sealing faces is measured with a contact-type profilometer (Mitutoyo SJ-210) per ISO 4287. Hardness is verified by Brinell or Rockwell tester on a batch sample basis. Both records are included in the quality documentation shipped with finished machined forgings.
When forging and machining are with one supplier, there is no boundary dispute when a dimension is non-conforming. Is the non-conformance due to a forging undersized condition, a machining datum error or a worn cutting tool? With integrated supply, Shivam Forge owns the answer and the corrective action — no blame-shifting between two separate vendors.
Moving forgings between a forge shop and a separate machine shop adds a minimum of 1–2 weeks to lead time: outbound transport, incoming inspection at the machining shop, scheduling queue and return transport. Integrated forging-and-machining at Shivam Forge eliminates this entirely. Typical machined forging delivery is 5–8 weeks versus 8–14 weeks for split supply.
A machine shop that did not forge the part does not know where the forging datums are, how much skin needs removing in the first turning pass, or where the forging flash line runs relative to the machined surface. Shivam Forge's machinists program from first-hand knowledge of the forging geometry, which reduces scrap rate on the first machining pass and gives better surface finish consistency.
One supplier generates one complete documentation pack: forging material certificate, heat treatment record, machining inspection report (CMM dimensional report), surface roughness record and hardness certificate. For export customers, this single pack is easier to manage than integrating documents from two suppliers with different formats and signatory authorities.
Machined forgings sourced from European forge-and-machine shops carry European labour rates on both the forging and machining operations. Shivam Forge's Rajkot facility applies Indian labour rates to both. For machined forgings with significant machining content (bearing housings, knuckles, flanges), the combined saving is typically 35–50% versus a European one-stop supplier.
Our ISO 9001:2015 certification covers the full integrated process: material procurement, forging, heat treatment, CNC machining, grinding, inspection and despatch. The quality system does not have a boundary at the forge-machining handover that creates documentation gaps. One certificate, one quality manual, one audit scope for the entire supply process.
Shivam Forge provides integrated forging and CNC machining services at Shapar GIDC, Rajkot, Gujarat — delivering fully machined forgings from raw billet to finished part under one roof and one quality system. Our machining capabilities include CNC turning up to Ø800×2000 mm, VMC milling on 1000×600 mm tables, surface grinding to Ra 0.4 μm, OD and ID cylindrical grinding, drilling, boring and tapping in all carbon steel, alloy steel and stainless steel forgings. Final inspection is performed on a 3-axis CMM, with dimensional reports provided with every production batch. We achieve IT6/IT7 bore tolerances and Ra 0.4 μm on bearing seats as standard.
The practical problem with splitting forging and machining between two suppliers becomes clear at the first non-conformance. A bore that is 0.05 mm undersize on the machined forging — is it because the forging was undersized and the machining datum was wrong, or because the CNC program was incorrect, or because the boring bar was worn? With two separate suppliers, neither owns the full picture. With Shivam Forge's integrated service, we forged the part, we know the forging geometry, we set the machining datums and we did the CNC boring. We own the investigation and the corrective action entirely.
Heat treatment sequence relative to machining is a detail that matters for dimensional stability. Quench and temper heat treatment introduces dimensional changes (typically 0.1–0.4 mm per 100 mm dimension depending on grade and section size) that must be accommodated in the pre-heat-treatment machining allowance. When a separate machine shop receives already-heat-treated forgings, they must programme to the actual post-HT dimensions measured on the forging — which can vary batch to batch. Shivam Forge plans the machining sequence from knowledge of the heat treatment dimensional change data accumulated across our 20+ years of production, giving more consistent finished part dimensions.
For automotive OEM and export customers, the documentation package from an integrated forging-machining supplier is simpler to manage. One supplier generates: the forging material test certificate (with mill heat chemistry and spectrometric verification), the heat treatment record (temperature-time charts and hardness certificate), the CMM dimensional inspection report, the surface roughness record and the hardness verification on finished parts. All documents carry the same part number, batch number and supplier name — they form a coherent quality record without the reconciliation required when documents come from two separate suppliers in different formats.
Shivam Forge's integrated forging and machining services are used by 500+ OEM clients across automotive, agricultural equipment, oil & gas, pumps and valves, and industrial machinery sectors. We export machined forgings to 12+ countries. For purchasing managers evaluating a move from split forging-machining supply to integrated single-source supply, we recommend starting with a pilot batch: send us one drawing, we will quote the combined forging-machining price and lead time, and you can compare directly against your current two-supplier total cost and lead time. Contact us at +91 92657 72827 or email sales@shivamforge.com.
We perform CNC turning (up to Ø800×2000 mm), VMC milling (1000×600 mm table), surface grinding, cylindrical grinding (OD and ID), radial arm drilling, VMC drilling, boring (up to Ø400 mm) and thread tapping (M5–M64). Surface treatment (zinc phosphate, black oxide, zinc plating) is available through approved nearby subcontractors.
CNC turning achieves IT6 on bores and journals (±0.013 mm on Ø50 mm bore, for example). Cylindrical grinding achieves IT5/IT6 on OD and Ra 0.4 μm. VMC positioning tolerance is ±0.02 mm. Flatness on surface-ground sealing faces is ±0.01 mm. Bore positional tolerance is controlled by CMM verification.
For existing die profiles with standard grade materials, machined forging lead time is 5–8 weeks from purchase order. New parts requiring die manufacture add 2–3 weeks to this timeline. For repeat orders with approved first articles, lead time reduces to 4–6 weeks.
Shivam Forge at Shapar GIDC, Rajkot offers one of the most complete integrated forging-and-machining services in India, covering hot forging, heat treatment, CNC turning, VMC milling, grinding and CMM inspection under one ISO 9001:2015 quality system. We supply 500+ OEM clients across automotive, industrial and export markets.
Yes. We machine stainless steel (SS304, SS316L, SS410, 17-4PH) and duplex stainless (2205, 2507) forgings on our CNC lathes and VMC machines using appropriate cutting tool grades (coated carbide for stainless, PVD-coated inserts for duplex). Correct cutting fluid (sulphur-free for stainless) is used to prevent contamination.
Yes. All machined forgings are measured on our 3-axis CMM and a dimensional report with actual vs. nominal for all critical dimensions is provided with every batch. First article CMM reports include all drawing dimensions; production CMM reports cover critical and major dimensions per the approved control plan.
For existing die profiles, minimum order is 25–50 machined pieces. For new part numbers requiring die development, minimum is the prototype run quantity (5–25 pieces for first articles). We are flexible for R&D and low-volume industrial applications — call +91 92657 72827 to discuss your requirement.
Send your 3D model (STEP preferred) and 2D drawing with tolerances, material grade, heat treatment specification and required quantity to sales@shivamforge.com or call +91 92657 72827. We will quote forging and machining as a combined price with lead time within 48 hours.
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.
