+48 (33) 85 48 283, +48 (33) 85 85 111

What do we produce?

forgings

Forgings

semi-machined parts

Semi-machined parts

machined parts

Machined parts

Production Divisions

The process of forging and finishing

The basic technology in the production of forgings, made at Kuźnia Polska, is the hot forging of die forgings weighing up to 25 kilograms using forging presses, crank presses with Direct Drive System, forging automatic – Transfer, air hammers and upsetting machines.

1

Steel warehouse

We use high quality carbon, alloy, stainless steel in over 100 grades storing them onto the area of 4000 m2.

2

Heating and cutting room

Heating of sheared pieces of steel, called charges, to  temperature of 1,200˚ C in electric induction furnaces or gas-fired furnaces and their subsequent forming of the required element in a die.

3

Forging

In the forging of forging-crank-operated forging presses of 10 to 25 MN pressure, air hammers with a striking forth (hit energy) between 1,600 to 10,000 KGm and vertical and horizontal forging machines with 2 to 12 MN pressure are used. It is also possible to manufacture small mass forgings – i.e. from as little as 0.25 kilograms using PS-type screw presses.

4

Trimming

Removal of excess material in the form of fins – this is a dubbed trimming operation on crank or eccentric presses. During this stage of the production process aperture swaging, bending and calibrating is performed.

5

Heat treatment

Heat treatment of the forgings aimed at giving the forging high strength. In carbon and alloy steel forgings heat treatment in the form of quenching and tempering (quenching in water, oil or polymers), normalizing or isothermal annealing is used. Strength is also attained through a controlled cooling after forging.

6

Shot blasting

Shot blasting operation – cleansing of the forging’s surface of so-called scales (hard surface bloom resulting from steel oxidation at high temperatures). This operation takes place on special machines called shot blasters, which use steel pellets of great hardness and with a shot diameter ranging from 0.8 to 1.2 mm.

7

Calibration

Finishing operations including cold calibration, straightening, marking, grinding and burnishing.

8

Visual inspection

Meticulous visual inspection of each item in order to ensure 100% faultless forgings: with underfills, joggles, scale pitting, cold shuts.

9

Final control

Final control aimed at statistical checking of the quality of manufactured forgings and to provide a quality warranty through quality certification in accordance with the client’s requirements.

Our machines state

ModelQuantityDescription
HASENCLEVER 25002Crank press with forming force of 25 MN
SMERAL LZK25003Crank press with forming force of 25 MN
FICEP DD190 DIRECT DRIVE1Screw press, nominal power of 331 kJ and forming force of 24 MN
HASENCLEVER2Crank press with forming force of 16MN
DREHER1Crank press with forming force of 16MN equipped in TRANSFER
SMERAL LMZ16003Crank press with forming force of 16MN
SMERAL LZK10003Crank press with forming force of 10MN
HASENCLEVERFew smaller presses with forming force of 5 MN, screw presses with screw diameter of 180 mm and few hammers – 3000 kg ( hit energy 10 000 KGm ), 2000 kg, 1000 kg, 500 kg.
OLIVOTTOAutomatic heat treatment line – set up for 2008
LLR1000Press
KARL DEUTSCH UHW750/1,2, UH60MPI units

Machining

In order to meet Customers’ expectations, Kuźnia Polska S.A. has broadened its range of ready-made machined products. At present our stock of machining tools includes vertical machining CNC centers, CNC lathes with powered tools, which also perform drilling and threading, vertical and horizontal milling machines, turning lathes, drillers, relieving lathes and hydraulic presses. We produce mainly ready-made elements such as levers, flanges and towing hooks. Any process engineer, who designs the process, must also take into account a number of important parameters, which cover both the technological possibilities of the forging element (in other words giving it the desired shape) and the functional qualities, that the client stipulates, such as hardness, resistance, hardenability, structure etc.

1

Clamping devices

2

Machines

3

Hall

The Machinery:

Machine toolMaximum dimension of worked piece (mm)Maximum weight of worked piece (kg)
Machining centre – MAS QUICK 500500 x 500 x 400300
Machining centre – BROTHER TCR2B400 x 300 x 300120
Machining centre – Okuma MA 400600 x 500 x 500300
Machining centre – MAZAK VTC 200C1600 x 500 x 500650
Machining centre – 4940 YCM H400B500 x 500 x 600500
Machining centre – Okuma Multus B300Æ 250 x 700150
Machining centre – Okuma Multus U4000Æ 600 x 1500150
Machining centre – Miyano ABX-64SYY2Æ 165 x 12520
Lathe – Okuma ES L8MÆ 200 x 50050
Lathe – Okuma GENOS L250Æ 200 x 50050
Lathe – Okuma GENOS L300MÆ 300 x 450100
Lathe – Okuma GENOS L400Æ 300 x 500100
Grinder CNC – OKAMOTO OGM250UEX IIIÆ 200 x 50020

The basic premise of our strategy is to offer the product that is processed to a maximum degree. Currently it is approximately 25%.

We use:

  • machining (including pull broach)
  • zinc-nickel coating
  • phosphating
  • KTL protection
  • nitriding

We also offer only machining services without the forging process for some of our products.

Our strategy: to be a supplier of components for assembly lines.

Tooling Room

Kuźnia Polska disposes its own Tooling Room, serious modernized in 2005 being self-made toolmaker, ensuring the production processes so flexible as possible and offering very professional service outside. Continuously upgraded machines and IT systems are able to keep the highest market needs. Designing, engineering and programming of CNC centres are performed onto the advanced CAD/CAM positions. The leading software is CATIA.

We guarantee especially:

  • heat treatment of the tools and nitriding of the cavity surface in vacuum furnace
  • hardening of the tool steels and derivatives in vacuum furnace
  • 3-axle machining of the products in dimensions 2000mm x 1400mm x 700mm
  • 5-axle machining of the products in dimensions D=1100mm h=700mm
  • CNC lathe machining D=390mm L=500mm
  • electroerosion machining of the products in dimensions 650mm x 450mm x 350mm
  • electroerosion wire machining of the product in dimensions 500mm x 350mm x 200mm
  • programming of CNC tool machine – 2, 3, 5-axles

Among other thinks, we have:

  • catalytic nitriding furnace
  • WCL hardening work cell and derivatives in a protect atmosphere
  • WNC, WNLV hardening work cell and derivatives
  • heating furnace with carrying capacity of 3,5 tons

Our products

Forgings to passenger cars and trucks

Forgings to passenger cars and trucks

75% of the forgings produced by Kuźnia Polska, are dedicated to multiserial and repeatable manufacturing to automotive and truck branch.

Forgings to machines and agriculture industry

Forgings to machines and agriculture industry

15% of the forgings and machined parts work in special agricultural vehicles like tractors, harvesters and agro-equipment.

Machine industry

Forgings to machine industry

5% is different parts to modern engines, transmissions and road devices.

Energy and railway

Forgings to energy and railway

3% of our assortments supply the renewable energy and railway sector.

Forgings to air force

Forgings to air force

2% of the production is advanced technology fortified by the highest quality demands for air force industry.

Call our company:

+48 (33) 85 48 283

+48 (33) 85 85 111