In the off-highway industries, equipment must offer reliable performance in unpredictable and rugged environments. To meet the rigorous requirements of these industries, manufacturers use forging to produce strong and durable machine parts that ensure dependable, high-performance operation of the machines employed.

At Cornell Forge, we are an ISO 9001:2015 certified company with over 90 years of experience in producing net, near-net, and finished forged products for a wide range of industries, including off-highway. By working closely with our customers in the off-highway industry, we produce steel and alloy forgings that meet the industry’s standards for strength and durability.

Advantages of Forging

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Forgings in the Off-Highway Industry

The forging process applies high levels of pressure to cold or hot metal to produce parts suitable for use in the off-highway industry. Forged products offer a number of advantages over parts produced through other production methods, such as:

  • Higher strength. The uniform size of the grains in the forged metal and their alignment with the overall shape of the forged part increases the part’s strength-to-weight ratio, making it capable of withstanding higher torques. 
  • Greater flexibility and machinability. Forging improves the chemical purity and uniformity of the metal by expelling impurities and eliminating the segregation between alloys. These processes also result in greater structural integrity and flexibility and make the material easier to machine.
  • Better toughness and reliability. The improved characteristics of the metal make it tougher and more reliable, allowing the parts to last longer and have lower warranty-related costs.
  • Superior heat resistance. The forging process gives the metal greater structural integrity, improving its ability to retain its metallic characteristics over a broader temperature range.
  • Lower production costs. Near net shape forging produces parts that are close to the final shape. This process generates less scrap as the parts require little to no post-processing.

Forged parts find application throughout the off-highway industry, particularly in engine and transmission systems. Examples of typical parts employed include:

  • Forged Gears: Gears and gear blanks are available with a variety of teeth sizes for a wide range of mechanical applications.
  • Forged Brackets: These components are suitable for use indoors or outdoors for heavy-duty load-bearing applications.
  • Forged Sprockets: Similar to gears, sprockets are used in power transmission applications across the industry. One common use is in the transmissions of off-highway vehicles and machines.
  • Levers: Levers, lever nuts, and lever handles are extensively used in applications that need handles or involve OFF/ON operations.
  • Spindles: Forged spindles are preferred for off-highway applications since they are more reliable and durable than machined ones.
  • Wheel hubs: As major load-carrying parts of vehicles, forged wheel hubs are preferable for off-highway vehicles due to their superior strength and durability.

Your Source for Off-Highway Forgings

At Cornell Forge, our experts have extensive experience in manufacturing standard and custom forged parts for the off-highway industry. Equipped with years of experience, our team has the skills and knowledge to provide customers with high-quality, innovative solutions at competitive prices.

One example of our successful delivery of a custom forging solution is as follows:

The customer approached us after having experienced frequent breakdowns of the multi-piece, fabricated sprockets in their off-highway vehicles. To resolve their issue, our experts created a one-piece, forged sprocket designed using solid modeling techniques, forging design simulations, and comprehensive life cycle testing. The end result was a stronger, more reliable, and more affordable sprocket component.

Work With Our Team of Forging Specialists

At Cornell Forge, our forging specialists work with carbon and alloy steel up to 100#s, stainless steel up to 30#s, and titanium up to 10#s. We also offer related services like metallurgical consulting, concurrent engineering, heat treatment, and hardness testing.

To find out more about our forging capabilities or to partner with us on your next forging project, contact us or request a quote today.