Brooks Forgings Ltd

Brooks Forgings Ltd was recently approached to produce special arching horns that are commonly used in overhead electrification applications for the railway industry.

A combination of sawing, machining, hot bending and welding processes was used to produce the various components used in the overall arching horn assembly. Brooks Forgings has all of these processes available on-site, ensuring the swift turnaround and quality tolerances required by the customer.

All of the components were produced from fully certified 316 stainless steel material of European origin. The profiles, produced from 6mm thick plate, required the machining of special chamfered edges prior to the hot bending process that used specially designed tooling and jigs to minimise deformation and meet strict tolerances. The profiles were then fillet welded to a prefabricated clamping block that was produced firstly as a one piece, drilled with two 10.5mm holes and a large 24mm hole, and then sawn in half to create a matching pair. The complete assembly was then checked for distortion following the welding process. Supplied complete with A2 stainless bolts, washers and stiff nuts.

Brooks Forgings Ltd was recently approached to produce special lifting assemblies that are used to safely lift and relocate heavy industrial stillages.

Our client, originally importing components from abroad, was let down on delivery.

Brooks Forgings was happy to step in and provide an on time solution that was achieved due to the extensive on-site manufacturing capabilities available.

The overall assembly comprises of a link and eye bolt, produced from high tensile material. The M20 eye bolt was designed to function with a working load limit of 2 tonne and fully drop forged, machined and threaded in-house. The link, manufactured from 20mm diameter material, was hot bent and flash butt welded, also on-site, allowing for heat treatment.

Once assembled, each component was tensile tested on-site to provide the necessary certification required by our customer.

The order was fulfilled on time and excess stock held in our warehouse for future urgent requirements.

Brooks Forgings Ltd is a diverse manufacturing company specialising in the Hot Forging, Machining and Fabrication of metal components.

We have prepared this article to inform potential customers of the numerous processes that a single component can travel through during its production life.

The recent addition of a 3D printer and the latest QForm forging simulation software, working in unity with existing SolidWorks software, has the potential to transform the way the company does business in the early stages of product development.

Please contact our team today for more information.

1. 3D Design

Solidworks is industry-leading 3D design software that provides part, assembly, and drawing capabilities with the added benefits of stress analysis, cost estimation, rendering and animation.

Brooks Forgings currently has 3 seats enabling 3 fully trained design engineers to use the software at one time.

Typically, when a client approaches Brooks Forgings with a viable component for manufacture, they can only provide a worn physical sample or obsolete drawings. The first step in production is to take all of the available information and create a new scaled model in Solidworks. Once generated it enables the creation of detailed digital 2D drawings, 3D renders and can even be exported in a format for 3D printing.

2. 3D Printing – Additive Manufacturing

3D printing enables the low-cost production of prototype parts with incredible accuracy.

A physical and dimensionally accurate component can be 3D printed and handed to the client, giving them the ability to finish machine and even implement into a sub-assembly for final suitability testing.

The benefits of this capability are particularly evident in the early stage of production. Forging is an industry with high outlay costs and production of tooling and purchase of raw materials often reaches in excess of £20,000. 3D printing can assist in avoiding costly mistakes caused by the production of incorrect dies and ultimately scrap material.

3. Stress Analysis

Various types of Stress Analysis are incorporated into the latest Solidworks package, enabling Brooks Forgings engineers to carry out simulation on either individual parts or assemblies by using finite element analysis. This process can improve and validate performance and reduce the need for costly prototypes or revisions later on in the project.

This also enables us to evaluate product structure and design suitability and make alterations to suit various requirements. We can also input various material properties making the system fully customisable

4. QForm Forging Simulation

QForm is forging simulation software that enables the development and optimisation of tooling and accurately simulates and analyses the forging process.

Why is this so important? It is possible to identify flaws such as inadequate impression filling, laps or folds, and flow-through defects.

Further optimisation of the process can be achieved by varying starting material diameter, forging forces and analysis of die tooling stresses to improve durability and longevity.

The combination of 3D printing and QForm enables Brooks Forgings to improve lead times and the overall efficiency of the manufacturing process by eliminating forging defects and final application suitability issues before final production tooling and samples are physically produced.

5. Die Cutting & Sinking

We have an extensive on-site tooling room that provides complete control and flexibility throughout production. Our machining department plays a key role, enabling a quick turnaround of forging dies when required.

This process is combined with the latest CAM software that gives us the ability to run die cutting simulation to identify potential errors in final tooling production. Tooling is a crucial part of the overall manufacturing process and is the most costly.
6. Drop Forging

The Drop Forging process is just one of many offered by Brooks Forgings Ltd. The shackle in this case study was manufactured using our Banning GOA 1250 drop hammer. Our forging processes utilise induction heaters that are automated with automatic hopper feeds. This supplies the operator with a constant and controlled supply of billets at optimal forging temperature.

7. Machining

We currently have 13 CNC machines enabling us to finish machine components as batches come off the forging production line. For the machining of the drop forged shackles in this case study, special quick release jigs were designed and made by our tool room. Two sets of jigs were used, one that allows the facing of the shackle ends and the other to drill the final pin hole.

Brooks Forgings Ltd, a leading UK manufacture of forged, machined and fabricated components, is celebrating its 55th anniversary.

Established in 1960, the company has grown to become a leading UK manufacture of forged, machined and fabricated components. Thanks to a substantial expansion in 2010, the company’s facilities now cover an impressive 95,000 sq. ft. over two sites located in the West Midlands.

The expansion in 2010 saw the relocation of the manufacturing plant to a new 45,000 sq. ft. site, formally Hayes Tubes, located in Balds Lane, Stourbridge. This has given the company room to grow through continued investment in its capabilities, reinforcing its future in British Manufacturing.

Now with over 20 manufacturing processes including:

• • Upset Forging
  • Drop Forging
  • Open Die Forging
  • Horizontal Counterblow Forging
  • Hand Forging
  • Machining
  • Thread Rolling
  • Ring Rolling
  • Fabrication
  • Robot Welding
  • Flash Butt Welding
  • Bending - Hot & Cold
  • Pressing – Hot & Cold
  • Swaging & Pointing
  • Tensile & Destructive Testing
  • Computer Aided Design & Machining
  • Marking & Traceability

It is this diversification that enables the company to offer a ‘one-stop-shop’ service to its customers requiring forged, machined and fabricated components. One of the key advantages is improved lead times. For example, when components come off the forging line they can immediately move to a secondary operation such as hot bending or machining and then to final assembly/fabrication. This rotational method of production also offers full traceability and improved quality control.

The vacant manufacturing facility at Doulton Road, Cradley Heath, was fully refurbished to house new warehousing facilities, allowing a capacity of up to 2500 pallets of stock. Standard components are held in stock, enabling immediate despatch. Our warehousing facilities are offered to customers requiring orders on a ‘call off’ basis, primarily for components made to customers’ requirements.

Quality is of upmost importance in the manufacturing industry and Brooks Forgings are constantly keeping up-to-date and in conformance with the latest accreditations. The company currently holds Lloyds ISO 9001 for Quality, ISO 14001 for Environmental and OHSAS 18001 for Health & Safety. In 2014 the company was audited for and successfully obtained CE and National Highway Sector Scheme approval. These give us the independent checks and systems to monitor and improve our in-house performance, giving our customers the independent quality assurance that they expect.

Another step forward in quality management is the recently completed construction of a new central control room. This manages all aspects of production and will play a vital part in the continued growth of company. Several systems will be linked, including software controlled heating furnaces, CNC machines and computer terminals throughout the facility. The newly designed and built furnaces, 4 in total, are capable of reaching temperatures of 1300°C and feature a 7 day start up and shutdown timer along with a separate idle and working temperature setting. Computer terminals will enable us to fully monitor job performance and offer full ‘live’ route card tracking of components throughout production. Our 13 CNC machines now have full WIFI capability allowing remote programming and problem solving.

Businesses that would like to find out more please contact us on 

01384 563356

, email enquiries@brooksforgings.co.uk or visit our website www.brooksforgings.co.uk

The Garden Bridge is a £175 million pound project to build a 366m-long ‘floating garden’ over the River Thames, planned to begin in January 2016. Set to become a world-class landmark, showcasing the UK’s expertise in design, engineering and landscaping, Brooks Forgings are proud to announce their involvement in the project.

The Project - Overview

The Garden Bridge will stretch from the top of Temple underground station on the Northbank to the South Bank. The bridge will hold an expansive garden. Footpaths will weave through the garden, creating a new pedestrian route which will be free and open to all between the hours of 6am–midnight.

The garden will be an enchanted space in the middle of the busy city. It will feature an abundance of plants, trees, and shrubs indigenous to the UK, Northern Europe and other parts of the world. These have all been chosen for their biodiversity, bringing wildlife and horticulture to the heart of London. The planting has been carefully designed to ensure that it will frame and enhance views of the iconic landmarks of London.

The garden consists of several sequential spaces, designed to reflect a number of different characteristics of the rich cultural heritage of the capital’s river and both river banks so that a pedestrian crossing the bridge will walk through an ever-changing seasonal landscape.

The south end will have a more relaxed aesthetic, featuring plants reflecting South Bank’s marshland history such as willow, birch, alder, geranium, violet, and primrose.

At the north end, planting will be inspired by Temple Gardens’ history of ornamental gardening, featuring wisteria, magnolia, roses, alliums, irises and summer snowflakes.

Holding the garden will be a beautifully engineered copper-nickel structure. Its warm colour will provide a contrasting finish to the stone and steel structures that characterise the architecture on both sides of the river.

The bridge has been designed to offer pedestrians a series of unique spaces throughout the garden, providing a sense of intimacy on your journey across the River Thames. There are opportunities to stop and look, to explore and meander through the gardens, or walk directly across as part of a wider journey.

The Garden Bridge will be created for the enjoyment of people for generations to come. This new landmark will showcase the best of British design and will be used by all, becoming a cherished part of London’s landscape.

The Balustrade - Design & Manufacture

Designers for the project have generated an ambitious design for the balustrade that will span a total of approximately 1000 meters in various locations throughout the project. Conventional balustrade is typically produced from round or square material, however, the material chosen for this project has a ‘flower’ shaped profile. Selected to be aesthetically pleasing and in keeping with the theme of the project, it creates several challenges in the manufacturing process.

The balustrade consists of 2 separate designs produced using the same material, requiring tooling for 2 different head formations and 2 different base formations.

Brooks Forgings in-house production and design team analysed the design and spent several weeks designing tooling to ensure the best quality component could be produced using the most effective manufacturing process.

It was crucial that the profile of the material blended cleanly into the head and fluted base of the balustrade components with no mismatch or unclean edges.

The Tooling For The Project Was Very Complex And Required On a Short Lead Time.

A total of 4 die sets were produced using the latest Solidworks CAD and CAM software. This allows the production of 3D models, product & tooling drawings and simulates both tooling and die cutting processes.

The 13 CNC machines at Brooks Forgings are WIFI enabled, allowing remote programming and problem-solving from the central control room by one of several technical engineers. The tooling for the project was created using this process, sent remotely to one of several vertical CNC machines for production.

Brooks Forgings are pleased to announce their involvement in a very special locomotive restoration project.

Our client is directly involved a modern build of the new P2 Mikado 2007 Prince of Wales, in its day one of the most powerful express passenger locomotives to operate in the UK.

We were approached to look at forging the foundation ring corner blocks, an integral part of the final boiler assembly. This was primarily to solve a problem that had developed with a flame cut version of the component produced from raw plain material, a design used on a similar boiler fitted to the A1 Class 60163 Tornado. Subject to constant temperature changes and varying loads, fatigue cracks started to appear. It was clear at this point that other methods of production needed to be explored and our client decided to source a stronger forged alternative.

With a focus on the material grain flow, it was decided to start off by hot bending the plain material to the rough desired shape. This means that the grain flow follows the contours of the bend.
The bent material was then drop forged to achieve the final ‘blank’ form, further compressing the grain flow to provide the strength required. The forged blanks were then fully machined to the final specification.

The newly forged and machined foundation corner blocks were supplied on time and are now fully installed and in use on Tornado.

Brooks Forgings is always looking for new developments in technology that can help achieve and surpass the strict quality standards required for metal components supplied into many industries across the globe.

The latest addition to our Quality Control department is a Marposs Merlin gauge computer. Primarily designed for the shop floor environment, the Merlin is used for measuring applications and gathering statistical information.

The Merlin allows effective collection of data from up to 32 traditional or wireless measuring devices. This includes statistical process control that allows multiple measurements, data segregation and product batch tracking, all displayed in real time with on screen numeric and graphical layouts. Electronic bore and snap gauges are currently used in our machining processes, allowing immediate and accurate inspection of machined internal and external diameters.

Prior to any measuring procedure, batch codes are allocated to maintain full batch traceability and a calibration routine is performed using fully traceable calibrated setting masters, ensuring accurate data is recorded.

For ease of use by the operator, measurement values are recorded and displayed in a colour coded format, both graphically and numerically on the Merlin’s LCD screen. This allows the operator to adjust settings in the manufacturing process to prevent the manufacture of non-conforming parts and aid continual improvement of the overall process.

Brooks Forgings Ltd is proud to announce that we are now fully registered as a supplier on Achilles Link-up (RISQS).

Supplier Number: 182325.

RISQS, formally known as Achilles Link-Up, is an independent, third party qualification assessment of a supplier’s capability to supply products and services into the rail sector.

Fully supported by Network Rail, LUL/Transport for London, passenger, light rail and freight train operators, rolling stock organisations, main infrastructure contractors and other rail products and services providers in the management of supply chain risk.

Brooks Forgings Ltd is proud to announce the launch of a brand new website.

We have made substantial investment to develop and transfer over to a fully responsive design, now supporting mobile, tablet and desktop platforms. Already regarded as one of the most extensive websites in the industry, we have taken this opportunity to improve user experience and offer further insight into our manufacturing capabilities.

Our manufacturing and product photo gallery is a new addition we are excited about, currently containing over 2000 images!

We have also added a comprehensive PDF library covering all of our processes and products, all downloadable for future reference from the media section of the website or directly from the appropriate product or process page.

We encourage people to have a good look around our website and welcome any new business opportunities for 2015.

We have recently completed the construction and furnishing of our brand new central control room at our manufacturing facility in Lye, Stourbridge.

The central control room will manage all aspects of production and play a vital part in the continued growth of the company.

Several systems will be linked, including software controlled furnaces and computer terminals throughout the facility. Currently on trial, these furnaces feature full temperature control and programmed running cycles, making them more energy efficient. Computer terminals will enable us to fully monitor job performance and offer full ‘live’ tracking of components throughout production.

The installation of a 42 camera CCTV monitoring system in also linked to the office, ensuring all staff and visitors on-site adhere to the strict Health & Safety regulations.

Brooks Forgings are proud to announce that we have recently been audited for and successfully obtained CE and National Highway Sector Scheme approval. These approvals are essential for the continued manufacture and supply of components in to the Civil Engineering sector.

CE marking demonstrates a product’s compliance with applicable EU legislation and its legitimacy to be placed on the market within the European Market. As of the 1st of July 2014 CE marking became mandatory for fabricated structural steelwork components.

Our approval permits the supply and distribution of Non-Preloaded and Preloaded High Strength Bolting Assemblies.

The National Highway Sector Scheme (NHSS) approval is a bespoke quality management system based on, but not duplicating, the ISO 9001 standard. Split into several schemes it is designed to ensure that work is carried out to the highest standards. Brooks Forgings are now fully approved for the manufacture and distribution of Mechanical Fasteners up to M100 in accordance with National Highway Sector Scheme 3.

These new approvals reinforce our dedication in meeting the strict requirements demanded in the industry.

At Brooks Forgings Ltd we have the manufacturing capabilities to hot forge hammerhead bolts to DIN 186, DIN 188, DIN 261 and DIN 7992.

Sizes up to M100 and lengths of 6000MM are achieveable.

Our range of in house manufacturing capabilities enables us to rapidly manufacture specialist components and non-standard items to our customer's exact specifications.

Die Sinking, Upset Forging, Machining, Roll Threading, Finishing and Packing.

Quality to QC1, QC2 and QC3. ISO 9001, ISO 14001 and OHSAS 18001 approved.

Contact us today with your requirements.

To watch video please visit our website: https://www.brooksforgings.co.uk/news/12/2013/12

Brooks Forgings Ltd, winners of the Manufacturing Achievement award in the 2013 Made in Midlands Business Awards.

Expanding through diversification, Brooks Forgings Limited has made several steps to reinforce the company’s presence in UK manufacturing.

The relocation of our manufacturing base to a new dedicated 45,000 sq ft site, located in Lye Stourbridge, has given the company room to expand further. The redundant manufacturing space was fully refurbished and now houses a new warehouse facility capable of holding an additional 1250 pallets of stock.

Our range of on-site manufacturing processes is one of the most extensive in the UK forging industry, now covering forging, machining and fabrication. This capacity ensures full traceability and quality of components, but also reduces the reliance on sub-contractors. Lead times are improved by having a rotational method of production. Components can move onto the next process, machining for example, while the batch quantity is still being forged.

The Installation of a Model C Chambersburg Automated Horizontal Counterblow System, possibly the only operational machine in Europe, enables us to achieve higher volume production whilst using less energy through the use of programmable energy levels and blow patterns.

Over the last year we have also made key investment in strengthening our machining capacity. The purchase and installation of several additional CNC Lathes and Vertical Machining Centres increases our current machining capacity to 14 machines.

In July 2013 the company was audited for and subsequently awarded certifications in ISO 14001 for Environmental Management Systems and OHSAS 18001 for Health and Safety Management Systems. The company is also seeking CE approval by the end of Q4 2013.

Image: Left to Right. Clive Brooks - Chairman, Richard Noble OBE, Steve Brooks - Managing Director and Adrian Brooks - Financial Director.

Brooks Forgings Limited is pleased to announce it has been audited for and successfully obtained certifications in ISO 14001 for Environmental Management Systems and OHSAS 18001 for Health and Safety Management Systems.

This confirms that the protection of the environment and the prevention of pollution is of prime importance, and is essential to the successful operation of the business, and the well-being of future generations. Also, the promotion of good Health and Safety measures is a mutual objective for all management and employees at all levels.

For a copy of all Quality, Environmental and Health & Safety policies and certificates please visit our downloads page.

https://www.brooksforgings.co.uk/news/8/2013/14

At Brooks Forging we have the manufacturing capabilities to hot forge hammerhead bolts to DIN 186, DIN 188, DIN 261 and DIN 7992. Sizes up to M100 and lengths of 6000MM are achieveable.

Our range of in house manufacturing capabilities enables us to rapidly manufacture specialist components and non-standard items to our customer’s exact specifications.

Case Study

A recent project, for a client in Europe, was the production of hammerhead bolts to DIN 7992 in grade 10.9 material, finished in black oxide. Sizes M48 to M100 and lengths from 1900MM to 3100MM.

Forged on site at our manufacturing facility in Stourbridge, West Midlands, special lifting jigs were put in place to assist the forging operators. With the average bolt forging weighing 135KG, safety was of upmost importance.

The ends were drilled and tapped M16x32MM, to enable the use of lifting eyebolts when moving the bolts on site. The ends also included directional slots, used as a visual aid during installation.

Testing was carried out to customer specifications. This included Ultrasonic, Magnetic and Liquid Dye Penetrant examination as well as Brinell and Charpy testing.

A complete Quality plan was provided for each bolt size, a strict requirement, ensuring full tractability for every stage of production.

A recent project was to manufacture several specialised eyebolts, required for a lifting cradle used in nuclear applications.

A recent project was to manufacture several specialised eyebolts, required for a lifting cradle used in nuclear applications.
Forged blanks were produced using 46mm diameter EN14 material, then normalised. Ultrasonic and Ultimate Tensile Testing was conducted on the forged blanks before machining.

The Eyebolts were then turned, milled and threaded with a specialised trapezoidal thread (TR40x7). Plug gauges were produced, using the mating component supplied, and each eyebolt throughly checked for compliance.

A product code was also chemically etched onto each eyebolt.

A complete Quality plan was provided with the components, a strict requirement, ensuring full tractability for every stage of production.

The latest addition to our Machining Department is a Doosan Model S310 SML CNC Turning Centre / CNC Lathe.

Complete with Sub Spindle, Driven Tools, Lemca Bar Feed & Fanuc 18-T Control.

Please contact us today to discuss your machining requirments.

Since the relocation of our manufacturing plant in 2011, we are constantly researching methods of reducing our overall carbon footprint.

One key area was to examine ways of improving process efficiency by reducing the number of operations and amount of energy required whilst at the same time maintaining component quality & reliability.

Automated & programmable forging
The implementation of more efficient forging procedures, for example Automated Horizontal Counterblow Forging, enable us to achieve higher volume production whilst using less energy through the use of programmable energy levels and blow patterns.

Energy efficient heating methods
Conventional forging heating methods rely on the use of brick furnaces, requiring a constant supply of fuel to maintain optimal working temperature. Working capacity is limited and prolonged heating times are needed to ensure material achieves forging temperature. At Brooks Forgings we have added automated Induction Heaters to many of our forging stations. Energy levels are kept to a minimum with the heaters only activating ‘on demand’ when the material triggers sensors on the feeding line. This improves cycle times and energy is only used when required, a crucial step in reducing carbon footprint.

Reducing costs, lead times and transportation footprint
Many manufacturers rely on the use of sub-contractors to complete different processes outside of their capability. This unfortunately increases cost, lead times, administration and the transportation footprint of the component. By offering an extensive range manufacturing processes in-house, we have reduced our transportation footprint for many of our supplied components by an estimated 70%.

Manufacturing efficiency through design & simulation
Brooks Forgings design engineers have access to the latest advancements in computer aided design and manufacturing. This enables them to perform pre-production forging simulations, estimate and evaluate thermal and mechanical properties throughout the manufacturing process and optimise results with minimal experimental trials. By actively reducing the risk of production errors we are able to keep material wastage to a minimum and improve overall process efficiency.

Dedicated warehousing for material stocks
Material stock is also considered valuable resource at Brooks Forgings. By having dedicated warehousing holding over 250 tonnes of stock, we have the capacity to purchase material in larger more economical volumes, minimising the requirement for multiple deliveries from suppliers. Lead times are again reduced by having the material available from stock. Wastage is kept to a minimum by internally marking, tracking and restocking material off-cuts.

The combination of manufacturing capability and efficiency is an integral part of reducing the carbon footprint for the company and its resulting supplied components.

As part of our continued expansion, at our Stourbridge manufacturing site, we have acquired a Banning GOA 1250 Drop Hammer.

This was one of several forging machines obtained from the purchase of Parker Hannifin's forging facility in Halesowen.

Extensive ground works were required to install the Drop Hammer. A full ground survey was undertaken to ascertain the soil & layer composition. This was to ensure the chosen location would be suitable to take the foundations and daily stresses and loads from use of the machine.

The completed installation pit measures 4300MM X 3700MM X 2100MM Deep.

Noise and vibration levels are reduced by 4 shock absorber seating pads below the machine.

The hammer is positioned to take full advantage of a Radyne 450KVA induction heater combined with a fully automated hopper feed. This supplies the hammer operator with a constant and controlled supply of billets at optimal forging temperature. The overall process increases production and reduces costs.

Please contact us today to discuss your Drop Forging requirements.

A Model C impacter system has been installed into the fully refurbished production site in Lye, West Midlands to further enhance the facilities available to our customers.

Impacters operate on the basis that two bodies of equal mass are accelerated towards each other at the same speed. When they collide the reaction forces are equal and opposite to each other concentrating the complete absorption of energy within the bodies themselves. When forging stock is placed between the bodies, it is deformed by the impact energy created by the blow. The impact energy is preset and is regulated by precise timing controls to provide consistent energy levels for metal deformation. Savings are made because only the required amount of energy is used for the size and complexity of the product being manufactured.

Sawn billets are loaded into a hopper which transfer’s them onto an automated production line. The billets are directed through a Radyne induction heater to heat the bars to the required temperature which are then picked up by a custom robotic arm system called the pallet feed. It is hydraulic servo driven and precisely locates the pre heated forging stock into the appropriate die locations. The combination of programmable energy levels, blow patterns and the programmable stock handling features mean the impacter is a fully automatic production system that has no reliance on manual manipulation skills whatsoever. Only contact between the stock and the die occurs, helping to provide a longer die life and a more consistent forging.

Clients can be certain they will achieve a more uniform product, an efficient manufacturing process, using less energy compared to other forging processes, and consistent, high volume production of excellent quality forgings with improved lead times.

We believe that the introduction of the impacter production facility will result in the lowest possible production cost for medium to high volume forging in the UK.

The expansion and refurbishment of the Brooks warehousing and storage facility based in Cradley Heath, West Midlands is now underway.

When complete will provide clients with more ‘Off the shelf’ product availability than ever before.

New racking and the purchase of specialist forklift equipment will transform the department considerably said Denis Villa, Project Manager. The improvements will enable us to work more quickly, safely and efficiently than before, providing a more streamlined distribution service and maximising valuable space.

Some clients use our storage facility to create their own ‘Virtual Warehouse’, he added, requesting us to import or bulk manufacture the items they want and asking us to store them. The additional space that is being made available for this part of the business will be a major benefit to similar clients, who have little or no space at their own premises.

We already have in excess of 2,500 pallets of stock ready for next day distribution so the product portfolio will also expand along with the 1000's of additional pallet storage spaces we will now have.

Any British metals business which has survived and prospered for the last 50 years is clearly getting a great deal right, especially when it remains in the hands of its founding family.

Black Country-based Brooks Forgings, which specialises in both forged and machined components, has earned a national reputation through its combination of traditional craft skills and the latest hi-tech equipment.
Its Global Sourcing division has traded successfully for 15 years, whilst its domestic manufacturing contracts range from the small and niche - including forgings for shotgun barrels - to the large and mainstream - such as backstays for the new Olympic Velodrome.

Its latest project is monitoring and reducing noise levels at its plants, as works manager Grenville Wakeman explains.

“In the past, we’ve had audiology tests done in the production areas, but as we’re just moving all our manufacturing operations to a new site in Lye, it seemed the right time to bring our strategy up-to-date.

“We heard of IHA (Independent Hearing Assessment) through the CBM, and asked Andy Williams to come in, to do both noise assessments and audiometry tests, and to look at every area; not just the machining department and the fabrication bay, but goods inward and even the sales office.”

Andy, who has operated nationwide from his Bromsgrove base for the last 18 years, was pleased Brooks decided to commission a comprehensive analysis.

“To be honest, a lot of people just ask for noise tests, which doesn’t give them all the information they really need, to prepare a proper action plan about conditions in their workplace,” he says.

“I spent two days at Brooks on the audiometric analysis, so they now have proper data on noise levels throughout their factory, and understand how employees might be affected.

“It’s also important to know how different options for noise reduction work. The HSE says wearing mufflers for too long can be a danger, and the ones which are too effective at blocking sound can make it difficult for people to communicate.

“Proper diagnostic screening can also have wider benefits, because companies then have precise data to demonstrate the actions they took to monitor and reduce noise, if a former employee was to make a claim for loss of hearing.”

The results of the IHA analysis - and the discount for CBM members - were much welcomed by Brooks, and Grenville says the resultant ‘noise map’ is being used to enhance its existing health and safety strategy.

“We now have a benchmark to work to for the future, and we even discovered in some areas where we had made ear protection compulsory, that it wasn’t needed.

“Andy has highlighted where ear and eye protection should be monitored, and we’re now considering installing automated meters, which will light up when a set decibel level is exceeded.”

To help reduce costs and lead times we have installed a Tosca automated shot blast machine.

Designed to allow for high production levels, whilst maintaining low running costs, of small and medium sized items.

The machine uses a hydraulic hopper feed and automated discharge belt, both rubber lined to reduce noise levels as much as possible.

The special anti-abrasive grooved belt ensures optimal rotation of components during blasting.

This, combined with our hand shot blast unit, means we should be able to handle over 40% of our shot blast requirements internally.

It is our intention, where lead times allow, to continue using and supporting our local reliable suppliers.

YANG Heavy duty Linear Lathe - ML60A

A recent addition to our Machining department is a YANG ML-60A heavy duty lathe.

This will give us the capacity to manufacture and finish larger components.

Delivery times should be reduced, large batch orders that are forged on site can be going through the final machining phase whilst forging is still taking place, ensuring the quickest turnaround possible.

Further information:

Spindle rotation with the four speed gear box provides high torque at any speed which makes the ML-60A suitable for turning and contouring any kind of material.

The 45 degree slant bed design contributes to reaching the goal of manufacturing automation by providing easy chip disposal, easy loading the unloading of work pieces as well as contributing to the rigidity necessary for stable cutting.

Multi-function turret with either 8-12 tool holders allows for more choices when determining machining operations. An optional VDI turning of any part shape. Faster change tooling over and high precision machining are easily achieved.

The locking power of the programmable tailsock can reach up to 5900 kgf, and its thrust force can reach up to 1650 kgf. The programmable tailstock can be efficiently positioned by programmed commands.

Easy maintenance is achieved by having a separate and movable coolant tank, chip conveyor and chip bucket.

High rigidity, high power efficiency (standard 22/26 kW, optional 30/37 kW), and large working area makes the ML-60A ideal for heavy duty machining.

High-tech linear guideways provide fast traverse speeds and ensure long lasting cutting accuracy by minimizing friction and thermal deformation.

Brooks Forgings Ltd exhibited at the Infrastructure Show from the 18th to the 20th October.

Many clients visted the Brooks stand during the show which proved to be a great success. It was an opportunity to catch up with existing clients and a pleasure to discuss forthcoming projects.

Our aim was to showcase the sheer variety of products we can manufacture whilst catering for the Construction, Public Services, Utilities and Transport sectors in particular

Foundation Bolts systems, Tie Bars, Eyebolts, Fasteners and Fixings are just a small selection of products that are available, all of which are project managed and manufactured under one roof, forming a single source of supply for our clients.

Many products we produce are manufactured to specific requirements with the Brooks team working from architects drawings or a sample product. Vistors to the stand were surprised by the selection of samples we had on display and further impressed when they saw the endless graphics of other products produced by us here at our factory based in Lye, West Midlands.

If you could not make the show and missed the team, why not browse the gallery section on our website or call us with your enquiry, we will be pleased to help.