Overcoming Challenges in Manufacturing a Defence Industry Component

In this article, we embark on a remarkable journey filled with valuable learning experiences as we encounter and successfully surmount unprecedented obstacles in the creation of a critical component for the defense industry. This narrative offers a detailed exploration of the entire process, from its inception to the triumphant achievement of our goals, highlighting the unwavering determination, expertise, and tireless efforts that propelled us to success.

The Project:

In our relentless pursuit of excellence, IQS Engineering undertook the formidable task of manufacturing a pivotal component for the defense industry. This endeavor was fraught with complexities, further compounded by rigorous quality standards, the imperative for precision, and the critical nature of the final product.

For a staggering 18 months, our client scoured the market in search of a company capable of producing the product according to their specific requirements. Sadly, their efforts yielded disappointment as previous attempts fell short of eliminating shortcomings such as porosity, hardness discrepancies, cracks, and underfilling.

When our client approached us with their needs and the persistent challenges they faced, we embraced the situation as a formidable challenge and were resolute in delivering a product that met their exacting quality standards. Some had even declared the product unattainable, further fueling our determination to prove that, at IQS, we thrive on achieving the seemingly impossible.

What Were the Challenges?

The component in question played a critical role in missile systems, housing explosives for launch. Precise dimensions, the capacity to withstand extreme temperatures, and optimal hardness levels were of paramount importance. Failure to achieve any of these criteria could result in catastrophic consequences, including the potential for life-threatening accidents involving our military personnel.

Steps to Development:

Analysis:

Recognizing the gravity of the situation and the stakes involved, we initiated Cross Functional Team (CFT) meetings to formulate a comprehensive plan for the entire lifecycle of the component, from initial design to final production.

Design Process:

Upon receiving the insights from the CFT meetings, the design process for the die commenced. Extensive computer simulations were employed to create a flawless design, with multiple iterations taking place to rectify any faults in the tool design. This process considered the various operations the die would undergo during forging. The inclusion of these operations introduced new challenges, and we continued refining the die design until we were confident it could withstand all required processes.

Once the die design was finalized, we programmed the die-making process and provided instructions to the VMC machine responsible for crafting the die or mold. The die-making process was arduous, taking a minimum of 7-8 hours to complete, with even minor flaws risking the failure of the entire process, necessitating a return to square one.

Die Design:

The die or mold is composed of two integral parts: a top portion and a bottom portion, between which the material for forging the product is placed. One crucial aspect of the design involved creating channels or gutters to facilitate the removal of excess material, known as flash, thus yielding a flawless component. Thoughtfully designed gutters also played a role in enhancing quality assurance.

Material Selection:

The client provided information regarding the type and grade of material to be used. Our task was to achieve the optimum hardness for the product within the constraints of this specific material, while simultaneously avoiding the risks of cracks and underfilling.

Forging:

After selecting the material and setting up the die, the forging process commenced. During the production of sample pieces for the client, we encountered a challenge related to precise temperature management. Achieving the ideal temperature for forging was critical to prevent brittleness. Although simulations had guided the process, the practical application exposed issues. Our collective experience in forging a wide array of materials came to the rescue, allowing us to devise an ideal heating-temperature management model that minimized brittleness and unwanted porosity.

Quality Assurance:

Compliance with the rigorous quality standards of the defense industry was non-negotiable, leading us to subject our forged product to a battery of tests and evaluations within the defense industry's stringent framework. Our sample products successfully met all the exacting requirements of our client.

Deadline Challenge:

Following the client's approval of the sample, we embarked on full-scale production. However, the client issued a new challenge, requesting 2,000 units within a mere 8-10 days. Continuous forging using the die inevitably resulted in wear and potential compromise of integrity and dimensions. Nevertheless, driven by our commitment to pushing boundaries and delivering exceptional customer service, we resolved to work tirelessly to meet the deadline. Our dedicated team worked tirelessly for 48-72 hours straight to maintain production and deliver within the stipulated timeframe.

Packaging and Delivery:

Ultimately, we successfully manufactured the product within the specified timeframe. Our team executed meticulous packaging and delivery procedures to ensure the secure transportation of this vital component, recognizing its significance in safeguarding our national security.

Conclusion:

Our journey in creating a component for the defense industry epitomizes our unwavering determination, expertise, and relentless commitment to excellence. Through collaborative efforts, innovative approaches, and unwavering dedication, we surmounted complex challenges and achieved our objectives. This case study serves as a testament to our capabilities, firmly establishing IQS as a driving force in the non-ferrous metal forging sector.