Forged components are characterised by a fibre-like structure that follows their geometry, much like the grain in wood, providing exceptional stability. This structural integrity is a key reason why forging is the preferred manufacturing method for critical components like bolts, supports, gears, and also pressure-bearing parts, including valve bodies, pipe fittings, and boiler parts. The optimised grain flow of forged parts results in superior mechanical strength and reliability, which is crucial for components operating under extreme conditions—unmatched by other processes like casting.
⚓️ This article builds on the introductory piece Grain Flow – Optimised Forgings for Enhanced Structural Integrity, where the basics of forging, in comparison to casting, were explained.
Lifting, Towing, and Securing: The Management of Critical Drag Forces
Drag forces play a crucial role in virtually all towing, lifting, and securing operations and are critical in both civil-industrial and military contexts. Whether it’s loading ships at a dock, operating cranes to lift heavy loads, or transporting materials at construction sites, or in agriculture and forestry (dual-use), these forces are key to ensuring the efficiency and safety of a wide range of activities. Understanding and managing drag forces is essential to ensuring the safety of both personnel and equipment during these operations.
The title image shows the grain flow simulation of a drop-forged hook with minimal flash on the outer edges (orange zones). In general, this flash material should be avoided as much as possible. Precision forging, combined with advanced forging simulation, helps to minimise this scrap. In the best cases, even completely flash-free forging is possible. This not only saves excess material but also reduces energy consumption. The image series below illustrates the bending process, where the grain direction in the steel follows the shaping, resulting in particularly robust hooks, shackles, or latches.
Latching & Locking – Securing Hatches and Breeches
For thousands of years, forging has been closely associated with military weaponry. From the creation of swords and armor in ancient times to the manufacturing of modern firearms, artillery, tanks, battleships, and submarines. The precision and reliability of forged components continue to be essential in the production of critical military equipment, ensuring durability and performance under extreme conditions.
⚓️ Examples of military precision forgings include forged track links for armoured vehicles, mounts for weapons and ammunition, as well as numerous forged components for high-performance engines. There is a ‘hidden’ subpage dedicated to military ordnance forgings and dual-use applications included in the author’s blog.
Precision-forged latches are just as crucial as hooks. Whether it’s about hatches on ships, submarines, or military armoured vehicles on the one hand, or cannon breech locks in defence operations on the other, latches play an essential role. The photo below shows forged latches with an integrated bolt screw, forged as one single seamless piece.
About the Author
After his military service as a guard commander at an airport of the German Federal Armed Forces, Thomas Henneke studied solid-state physics and mathematics, with a focus on energy-related topics and complex analysis. Following professional roles in research, education, and engineering, he has been the Technical Managing Director and co-partner of the German forging company KB Schmiedetechnik GmbH since 2010.
⚓️ On his blog at drop-forge.com, which complements the company’s main website, you will find additional information about their forging machinery, certifications, services, as well as articles on valves, materials, marine and naval applications, hooks and lifting gear, and a FAQs section covering precision forging, including tips on energy-saving practices in forging.
KB Schmiedetechnik GmbH is a highly certified forging specialist for drop-forged precision parts, located in Hagen, in the western part of Germany, between the “City of Blades” Solingen and Dortmund — best known as the “Football City.” The company is a member of the German Forging Association (IMU) and the German Association for Defence Technology (DWT).
Military Forgings for Critical Defence Applications, ranging from 200g to 130kg, across all steel grades.
