Press Forging Manufacturer in India – Hydraulic & Mechanical Press Forging
Shivam Forge manufactures precision press-forged components using hydraulic and mechanical press forging processes at our Shapar, Rajkot facility. Press forging delivers controlled, uniform deformation across the entire workpiece — producing large flanges, heavy gears, structural brackets and valve bodies with tighter tolerances, minimal flash and superior internal soundness compared to hammer forging. Force range 200 tonnes to 2500 tonnes.
Press Force Range
Dimensional Tolerance
Component Weight Range
Quality Certified
Controlled Force. Better Tolerances. Less Scrap.
Press forging applies a sustained squeezing force rather than rapid impact blows, giving the metal time to flow fully into the die cavity before the press returns. This controlled deformation penetrates deeper into the billet section, resulting in more uniform grain refinement, lower residual stress and tighter dimensional consistency than drop hammer forging — especially important for thick-section parts and complex geometries.
Press Forging Processes We Use
Hydraulic Press Forging
Hydraulic presses deliver a controlled, sustained stroke with programmable force and speed. The slow squeeze action ensures full die fill on thick sections and complex geometries — ideal for large flanges (DN100–DN600), valve blocks and structural components up to 500 kg where uniform internal structure is critical.
Mechanical Press Forging
Mechanical crank or eccentric presses deliver a precise, fixed stroke at high production rates. Best suited for medium-weight components (0.5–50 kg) requiring high repeatability and short cycle times — automotive brackets, connecting rod blanks, gear blanks and transmission components where dimensional consistency lot-to-lot is paramount.
Hammer Forging (Drop Forging)
Our drop hammer lines handle impact-sensitive geometries and thin-section components. Hammers impart energy through rapid impact, making them effective for complex thin-ribbed parts. We select hammer or press forging based on your part geometry, section thickness and required tolerance — not as a one-size-fits-all default.
Closed Die Press Forging
The majority of our press forging work uses closed impression dies machined from H13 tool steel. Billets of EN8, EN24, SAE 4140, 42CrMo4 or IS 2062 are cut to weight, induction heated to 1150–1250°C, and forged in a single or multi-blow sequence. Flash is trimmed hot immediately after forging.
Warm Press Forging
Selected components are forged in the warm range (700–900°C) to achieve tighter tolerances than hot forging while maintaining better die life than cold forging. Warm press forging suits medium-carbon steels (C45, EN8) for flanges and bushings requiring near-net form with minimal post-forge machining allowance.
Post-Press Operations
After press forging, components go through shot blasting, normalizing or quench-and-temper heat treatment, CNC/VMC rough and finish machining, and dimensional/metallurgical inspection. We supply machined and tested press forgings ready for your assembly line.
Components Manufactured by Press Forging
Large Industrial Flanges
Slip-on, weld neck and blind flanges from DN50 to DN600 in carbon steel (IS 2062), alloy steel (42CrMo4) and stainless steel. Press forging fills large flange dies more uniformly than hammer forging, reducing porosity risk in thick hubs and achieving face-to-face tolerances within ±0.5 mm as-forged.
Heavy-Duty Gear Blanks
Press-forged gear blanks in EN24, SAE 4340 and 20MnCr5 for gearbox, mining and wind turbine applications. Controlled press forging ensures the bore axis is perpendicular to the disc face as-forged, reducing machining stock and improving gear tooth root fatigue life.
Structural Brackets & Yokes
Thick-section structural brackets, tow hooks and yoke bodies for commercial vehicles and construction equipment. Press forging achieves the dense grain structure required for components subjected to dynamic bending and torsional loads. Material: EN8, EN24 or SAE 4140 to customer specification.
Valve Bodies & Blocks
Press-forged valve bodies, gate valve bodies and manifold blocks for oil and gas, chemical plant and high-pressure hydraulic applications. Hydraulic press forging ensures full die fill in thick sections with no internal voids — critical for pressure-retaining components tested to ASME/API standards.
Connecting Rod Blanks (Heavy Duty)
Large connecting rod forgings for diesel engines (bore 120–250 mm) and compressors in alloy steel EN24 or SAE 4140. Press forging the I-section shank controls flash distribution and produces a denser big-end/small-end interface than hammer forging on these heavier sections.
Wheel Hub & Spindle Assemblies
Press-forged wheel hubs and spindles for trucks (5–10 stud patterns) and agricultural tractors. The sustained press force fills the flange-to-barrel junction — the highest stress concentration — more completely than impact hammer, directly improving fatigue life at the stud circle.
Press Forging Advantages vs Hammer Forging
Controlled Force & Stroke
Press force is programmable and repeatable. Unlike hammer energy which varies with blow count, the press applies a defined load at a defined speed — critical for thick-section parts where penetration depth must be controlled to avoid cold shuts or under-filled corners.
Better Dimensional Tolerances
Press forging consistently achieves ±0.3–0.5 mm on critical dimensions as-forged. This reduces machining stock by 20–40% compared to hammer forgings of the same geometry, directly cutting material cost and machining cycle time.
Reduced Flash & Material Waste
Controlled die closing on a press generates 8–15% flash by weight versus 15–25% on hammer lines for equivalent parts. Over a production run of 10,000 pieces in EN24, the material saving is commercially significant — and less flash means lower trim die wear.
Larger Part Capability
Our hydraulic press lines handle parts up to 500 kg that cannot be produced on a standard hammer. The sustained press stroke reaches the center of thick billets where rapid hammer blows lose energy before full section deformation is achieved.
Lower Vibration & Noise
Press forging produces far less vibration and noise than drop hammer forging — important for factory structural integrity and operator health. This also allows tighter die guidance systems, contributing to better part concentricity and reduced die shift.
Consistent Grain Flow
The slow, controlled deformation of press forging gives time for uniform grain flow throughout the section. Hardness variation from surface to core is reduced compared to hammer forgings — translating to more consistent machined surface finish and predictable heat treatment response.
Shivam Forge operates hydraulic and mechanical press forging lines at our ISO 9001:2015 certified facility in Shapar, Rajkot, Gujarat — producing precision press-forged components for industrial, automotive, oil and gas, and structural applications across India and 12+ export markets. With a press force range of 200T to 2500T and component weights from 0.1 kg to 500 kg, we cover the broad middle ground between small drop forgings and large open-die forgings.
The core advantage of press forging over hammer forging is the nature of force application. A press closes slowly and squeezes the billet uniformly — the deformation front travels from the surface to the center of the workpiece. On thick-section parts like large flanges (DN200 and above), gear blanks with a wide face width, or structural yokes with deep web sections, this penetration depth matters enormously. Hammer blows decelerate before reaching the center of heavy billets; a hydraulic press does not.
Our press forging lines produce large industrial flanges (DN50–DN600 in IS 2062, 42CrMo4), heavy-duty gear blanks in EN24 and SAE 4340, connecting rod forgings for diesel engines and compressors, wheel hub and spindle assemblies for trucks and tractors, valve bodies for oil and gas service, and custom structural components from customer drawings. Flash rates on our press lines run 8–15% versus the 15–25% typical of equivalent hammer-forged parts — a direct material cost reduction.
Post-press operations at Shivam Forge include hot flash trimming, shot blasting, normalizing or quench-and-temper heat treatment to specified Brinell hardness, CNC and VMC machining to drawing tolerances, and full dimensional inspection. Material test certificates covering chemical composition, mechanical properties (tensile, yield, elongation, impact) and hardness are supplied with every consignment. For critical applications, third-party NDT (ultrasonic testing, magnetic particle inspection) is arranged on request.
Shivam Forge has supplied press forgings to OEMs and engineering contractors in Gujarat, Maharashtra, Tamil Nadu, Haryana and Punjab as well as export customers in Germany, UAE, USA, Australia and Southeast Asia. Our 20+ years of press forging experience, in-house die design capability and fast quote response (24 hours) make us the practical choice for procurement teams requiring reliable, technically competent press forging supply from India. Contact sales@shivamforge.com or call +91-92657-72827 to discuss your requirement.
Frequently Asked Questions
What is press forging and how does it differ from hammer forging?
Press forging applies a slow, sustained compressive force using a hydraulic or mechanical press, whereas hammer forging uses rapid impact blows. Press forging penetrates deeper into thick sections, produces tighter tolerances (±0.3–0.5 mm), generates less flash, and is better suited for large or complex parts where uniform grain refinement throughout the cross-section is required.
What press force range does Shivam Forge operate?
Our press forging operations cover 200 tonnes to 2500 tonnes. Light and medium components (0.1–50 kg) are produced on mechanical press lines, while heavy components up to 500 kg use hydraulic press capacity. Contact us with your part weight and geometry for a specific press line recommendation.
What materials can be press forged at Shivam Forge?
We press forge carbon steel (IS 2062, C45, EN8), alloy steel (EN24, SAE 4140, 42CrMo4, EN19, SAE 4340), case-hardening steel (20MnCr5, EN36) and stainless steel grades. Material selection is guided by your mechanical property requirements, operating environment and end application.
What is the size and weight range for press-forged components?
We produce press forgings from 0.1 kg to 500 kg and envelope dimensions up to approximately 800 mm × 600 mm. For very large flanges or structural forgings outside this range, contact us for a feasibility review — we may be able to accommodate via a combination of press forging and subsequent machining.
Can you supply press forgings with heat treatment and machining?
Yes. All press forgings can be supplied with post-forge heat treatment (normalizing, annealing, quench and temper to specific Brinell hardness), CNC rough machining, semi-finish or finish machining to drawing, and dimensional/NDT inspection. We supply ready-to-fit components for OEM assembly lines.
How do you ensure dimensional consistency in press forgings across large batches?
We monitor billet weight tolerance (±2%), forging temperature by calibrated induction heating controller, die condition by periodic first-article inspection, and finished forging dimensions by go/no-go gauging and CMM sampling. SPC (Statistical Process Control) charting is applied to critical dimensions on high-volume orders.
What industries use your press-forged components?
Our press forgings serve the oil and gas (valve bodies, flanges), power generation (gear blanks, coupling hubs), automotive and commercial vehicle (wheel hubs, connecting rods, steering parts), chemical plant (pressure fittings), construction equipment (structural brackets), and general engineering sectors.
How do I get a quotation for press-forged components?
Share your part drawing (PDF, DXF or STEP), material grade, weight/size, quantity and required delivery. We will respond with a detailed quotation including unit price, tooling cost, lead time and any DFM (Design for Manufacturing) comments within 24–48 hours. Call +91-92657-72827 or email sales@shivamforge.com.
Trusted forging manufacturer — Rajkot, Gujarat
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.
- Hot forging from quality alloy steel billets
- In-house CNC/VMC machining to drawing
- Heat treatment — normalizing, hardening, tempering
- CMM inspection and full quality certification
- Custom OEM forging from customer drawings
- Fast delivery from Shapar, Rajkot, Gujarat
- Export experience — Europe, Middle East, Americas
Factory Address
Plot No.3/B, Chaitanya Industrial Area, Shapar (Rajkot) – 360024, Gujarat