Brooks Forgings Ltd

We have designed, built and installed an automated forging transfer system onto forging machines based in our manufacturing centre in Lye, West Midlands.

The walking beam transfer unit makes the use of several compressed air cylinders to transfer the work piece from one die to the next and is easily capable of increasing output by up to 3 times that of conventional manual operation.

This technology also helps to reduce operator fatigue too, thus helping to provide a better ergonomic environment for our personnel to work in and to maintain consistent quality during the production process.

The automated forging line has the obvious benefit of enabling us to remain competitive in the market place and provide improved lead times for our clients.

A further two Multiforge machines have been earmarked for future automation as and when production demand requires.

Brooks Forgings were asked to produce an undercarriage component for use during re-fits of the surviving World War II Spitfire aeroplanes.

Using an old forging and a machine drawing, we created a model of the part in Solid Works then using 3D printing a resin model of the component was produced.

This enabled our client to fine tune the model to ensure the finished part could be machined to accommodate as many different variations of the Spitfire that took place during its colourful history.

Investigations were made to ensure optimum strength was maintained and the most economical method of production established.

The closed die forging process was employed to manufacture the part and is a tried and tested method of producing similar items worldwide. In this instance, it ensures the overall strength of the part by retention of the grain flow. The process also allows for significant reduction of complex machining after the forging process was complete thus reducing the amount of material used and leading to improved delivery schedules as well.

The product was then MPI crack tested after forging.

It’s great to still see them flying today, and for Brooks to play a small part in their history is particularly satisfying.

We are constantly looking at ways to expand our manufacturing capabilities.

With this in mind we have purchased 2 Panasonic robot welding cells to become a fundamental part of our fabrication facility.

Our tooling department have made special ‘three point’ location plates, enabling us to use our jigs & fixtures.

Plates are marked with the relevant program number for the corresponding welding cycle. This feature and the overall process should greatly reduce lead times.
 

The advantages to robot welding: 

· Faster welding cycle times
· No breaks in production
· Better quality welded product
· Less wasted material
· Consistent weld seam
· Higher precision, flexibility to reach hard-to-reach spots

We have installed 2 new sawing machines for our production site located in Stourbridge.

The first, a Bauer VG 450 ST Automatic, 6000mm long feed bandsaw, ideal for cutting single pieces or bundles, with long off-cut lengths
Featuring:

• 6000mm incremental feeder vice remains clamped to stock material
• NC control touch panel operation
• Cutting pressure control to reduce feed in solids
• 600mm cut height option

The second, a CH360HA-NC Twin pillar heavy duty fully automatic bandsaw with NC length setting. Ideal for volume production cutting of solid and sectional material. The modern fully enclosed design offers maximum operator protection.

Featuring:

• Inverter control of the blade speed with digital display (20-100mpm)
• N.C control with 9 programs for different lengths and respective quantities
• Multiple indexing with blade kerf compensation for long lengths
• Flood coolant system (option for micro mist lubrication)
• Detachable vertical bundle cutting vices Included Hydraulic mechanical swarf remover
• Material height sensor with rapid approach
• Powered blade cleaning brush
• Hydraulic blade tensioning
• Addimist micro mist blade lubrication system

Brooks (Forgings) Ltd specialise in the manufacture and supply of components for the Civil Engineering Sector.

A recent project involvd the production of M48 x 700mm Grade 8.8 Bolt complete with tube assemblies, designed the installation of a new crane track at a recently built Power Plant.

They had a tubular housing and 40mm thick washer plates and were machined at the end to take lifting eyes to aid installation.

By offering on-site hot forging, machining and fabrication our client was able to to get the complete product from one source... Brooks Forgings.

We're up to a maximum of 3 per week and it's set to increase further.

Our Global Sourcing Division has generated such demand from clients. They ask us to organise and fulfil their importing requirements, we are constantly taking delivery of products manufactured abroad and either stored in our warehouse for call-off and inspection prior to delivery onwards to our clients own facilities. How can we help you, call us now to find out.

60mm ‘Z’ bars were cold bent to fine tolerances without blemishing on the internal radius using specially manufactured ‘Stress Dissipating’ tools. The bars also required an internal thread, which was added before being despatched to our client.

From original samples and the remains of a gate catch, we cast, using SG Iron, 3-7ft replacement gate posts, 119 railheads and a new gate catch for a park refurbishment in Bilston. The whole project was completed and delivered to site ahead of schedule …it looks great, and will last for years!

Do you have a project that needs replicating? Call us today to discuss your requirements.

Brooks have installed a new Destructive Testing Machine alongside their manufacturing centre in Lye, West Midlands.

The machine has a break load capacity of up to 50 tonnes and enables them to complete tests in house right next to the production facility saving valuable time in the manufacturing process and reduce lead times.

Traditional metal-bashing skills and the latest computer aided technology have combined to make Black Country-based Brooks Forgings a nationally known name over it’s half century.

Still run by its founding family, it has expanded to operate from four sites across the region with divisions working on industrial and artistic ironwork products, eyebolts, U-bolts, shackles, galvanised fasteners, gates and bollards, as well as machining and global sourcing.

While still producing standard lines from stock, it is Cradley Heath based Brooks’ development of a range of specialist bespoke products that have made it a well known name.

Chairman Clive Brooks, who founded the business with the help of his father in 1960, said:

“Our clients talk to us because they know we recommend the best method of production for their job, project manage their work through the initial concept to design and then production to final delivery."

He added, “Our strength is our ability to produce virtually anything, often items our clients find difficult to source elsewhere. We have been known to purchase specialist equipment or to adapt existing machinery to ensure we are able to provide a quality product at a competitive price and in the shortest possible time. We have been able to remain true to our roots by retaining the traditional skills of the craftsman whilst embracing modern manufacturing technologies such as computer aided design, automated forging lines and robot welding machines."

The company has continued to expand through the recession, with it’s acquisition of a 45000 sq ft facility in Lye last year. Despite the recession, Brooks has also been investing heavily in new machinery, including a sawing line, two robot welding cells, three multiforges, and two further machining centres.

The firm has also installed a new destructive testing machine so that testing can take place alongside the manufacturing process. This prevents loss of manufacturing time as well as cutting the cost of sending items to external laboratories for testing. It also means clients can see parts tested on site.

Many years ago, when a false ceiling was installed at a theater company based in Staffordshire, the contractor inadvertently cut through the tie bar that was holding the walls together.

Several years later the surveyors noticed various cracks appearing in the walls and upon further inspection the fault was established.

Brooks were supplied with a sketch and produced the part that was needed. The fitting allows the severed ends of the existing tie bar to be re-joined and re-tensioned using a M24 turnbuckle. The tie bar is now doing the job it was originally designed to do and the walls have been stabilised.

Contact us now and let us to complete an ‘outstanding performance’ on your behalf.

Brooks Forgings were asked to produce ‘Backstay’s’ for the New Olympic Velodrome based in London.

Construction started on the Velodrome in March 2009 and will accommodate up to 6000 spectators in its 2 upper tiers and lower level seating areas located around its continual bowl.

The backstays which were made of 20 x 50mm flat Grade S275 Mild Steel have staggered leg lengths and stand at 1355mm Overall.

They are 200mm in width, completed with a 40mm ‘Cold Bent’ Radius bend at top corner and a 200mm difference in each leg length.

They will be fitted between seating sections running down the 47% incline stopping at the track and the infield area where the athletes will warm up during the games.

Contact us now to place your order with a winning team!

Our first full machine rebuild project is now operational with a second machine being rebuilt by our maintenance team.

It will be added to our existing range of 9 upset forging machines very soon and will have an automated forging transfer system that will significantly improve our output and efficiency on larger volume projects ….can we help you please, call us now!

Brooks Forgings specialise in the Upset Forging of components.

We were approached to manufacture both Left and Right hand versions of prestigious shotgun barrels. Hot forged, heat treated and straightened prior to full machining.

Call us now for a quotation!

Brooks secure Ministry of Defence contract to supply specialist 50 TONNE SWL recovery shackles, designed specifically for pulling tanks out of extreme conditions.

The shackles are manufactured on-site in the West Midlands and are supplied in the BZP Yellow Pass condition, complete with bolt and pin.

We can manufacture almost any shackle design in any size and finish required.

Contact us today to discuss your requirements.

Our new Cyclops 100B pyrometer has been purchased to aid our inspection team.

Temperature check results can now be downloaded via ‘bluetooth’ to our internal computer system, streamlining the completion of inspection and production reports even further.

We were approached by our customer to assist them with the supply of aluminium arms designed for the new Mini chassis welding production line.

The job involved bending a pre-formed flat aluminium arm whilst protecting the internal integrity of a pre-machined bore that ran through its full length. Careful monitoring of the optimum temperature range combined with correct forming tools, the product was successfully completed and ready for use within 6 working days of the order, exceeding all expectations.

Call us now to see how we can assist you.

One of our long established conservation clients asked us to replicate a ‘C’ scroll from free issue real ‘wrought iron’ for a restoration project they were working on in Liverpool.

Using an original sample supplied by the client, we produced special tooling that enabled us to recreate the scroll where the ends had to be tapered and then tightly wrapped in on themselves without altering the actual width of the finished product.

All the items had to have the same dimensions throughout the production run to maintain consistency and the special tooling we produced enabled us to achieve this yet retain the appearance and feel of a traditional blacksmith’s work at a fraction of the cost.

The client was pleased with the result, and the time it took to produce the consignment compared to how long it would have taken if they were all completed by hand.

Brooks invests in a paperless system with product drawings available to all of our manufacturing centres across any part of the company at the touch of a button.

Client communication is significantly enhanced with the ability for our personnel to access files immediately, to see and discuss drawings and specifications with clients first hand.

We also have the latest Stress Analysis Software and coupled with our modelling programme help evaluate stresses of new parts to enable our team to offer alternatives to alleviate possible failure problems of parts prior to manufacture. Clients, therefore get the best possible part for their application without any extra tooling cost or production runs being incurred.

Brooks add unrivalled quality control with the purchase and installation of the latest automatic ‘FaroArm’ measuring equipment.

The ‘Arm’ is portable and flexible, it has a magnetic chuck which can be fixed to a machine in situ, making the measurement of those larger, heavy or complex items easy, with an accuracy of up .005mm over a 1.2m distance.

The addition of the Faro Arm also enables us to minimise down time by reducing the use of multiple manual measurement devices generally used in a more traditional manufacturing environment. Measurement reports are completed automatically, can be tailored to individual customer requirements and saved or printed for future reference across any of our Manufacturing sites.

Brooks have extensive on-site Upset Forging capabilies, enabling the manufacture and supply of forged blanks and usages, also know as close nett forgings.

Forged heads can be on one or both ends of the bar and available off the shelf for immediate conversion into finished products.

Stocks are held as forged and some heat treated ‘Blanks’ which enables us to modify the length to suit our clients requirements and speed up the manufacturing process. This reduces lead times, and helps to alleviate minimum set up costs for small batches.

An additional benefit resulting from this practice is that off-cuts or waste become Bar Ends, which in turn are put back into stock for re-use at a later date, and so the recycling process starts again..

Brooks Forgings new production site based in Lye is now fully functional, increasing it’s combined manufacturing capacity to over 94,000 Sq ft.

Machinery that compliments existing equipment has been installed at the new site and will enable clients to benefit from increased manufacturing capability, efficiency, and quality.

This included the purchase and installation of an impressive array of equipment such as a sawing line, various robot welding cells, horizontal multi-forge and machining centres to name just a selection of what is available to our clients.

Further plans are in progress to add even more specialist machinery to this impressive manufacturing centre making Brooks the first choice for all your forging requirements.

Replication of Decorative Ironwork is a speciality at Brooks Forgings Ltd.

Our customer approached us to replicate a family emblem from a piece of stonework, for use in a fencing project. A relief pattern was created using the original stonework and a perfect copy was created in metal form.

We are heavily involved with local authorities regarding replication work for the restoration of heritage sites throughout the UK.

Contact us today with your requirements.

We were approached by a client to produce several components for use on the latest prestigious Triumph motorcycles.

Both brake and gear levers were required, manufactured using carbon Steel.

We have extensive on-site hot forging and bending capabilities, making this job ideal for us to manufacture without the use of sub-contractors... improving lead times.

Here at Brooks we have installed the latest stress analysis software which enables us to input material and heat treatment specifications direct from your design drawing.

This can show, with the assistance of coloured indicators, applied loads which will indicate where materials stress and breaks are likely to occur. A report can be provided for reference prior to start of the production process.

Want to know more? Call us today to discuss how we can assist you.