Forged steel and aluminium components as well as railway technology solutions for automotive, commercial vehicles, agricultural and construction machinery
Bharat Forge Global Holding GmbH
Ennepetal · Brand-Erbisdorf · Daun · Karlskoga (SE)New on Amplifa
About Bharat Forge
Bharat Forge manufactures high-strength forged parts from steel and aluminium in Europe for automotive (passenger cars and commercial vehicles), railway technology, agricultural machinery, construction machinery and defence applications. The portfolio includes aluminium lightweight components for chassis such as wheel carriers, control arms, swivel bearings, two-point links, structural and crash components as well as heavy steel forgings such as crankshafts, front axle carriers, steering knuckles, axle bodies and steering/tie-rod levers. Production is carried out by die forging and aluminium forging, complemented by the hot-padding process for axle bodies made of microalloyed materials, heat treatment, CNC milling and turning, automated welding (MIG, MAG, TIG), tool and fixture making as well as assembly of subassemblies. In railway technology, CDP Railsystems develops components for switch systems such as point roller units, switch and frog locks, slide chair and check rail plates and is a certified partner of Deutsche Bahn. As a development partner with CAE analysis and design optimisation, Bharat Forge supplies customers in Europe and worldwide from locations in Ennepetal, Brand-Erbisdorf, Daun and Karlskoga (Sweden).
- Site
- Ennepetal
- Processes
- Aluminium forging / lightweight forged parts, Steel forging / heavy steel forged parts, Die forging, Hot-padding process (axle bodies), Heat treatment (post-forging operations), CNC milling, CNC turning, CNC drilling
- Materials
- Aluminium, Aluminium alloys (high-grade), Steel, High-strength materials (axle bodies), Microalloyed materials (axle bodies), Plastics (CNC milling), Aluminium & Aluminium Alloys, Microalloyed Materials
- Certificates
- IATF 16949, DIN EN ISO 9001:2015, TISAX (VDA ISA), DIN EN ISO 14001:2015, DIN ISO 45001, DIN EN ISO 50001, HPQ (Deutsche Bahn)
- Founded
- 1646
- Industries
- Automotive (passenger cars/commercial vehicles), Railway technology/rail infrastructure, Agricultural machinery, Construction machinery, Defence
- 01
Design / CAE product development
- 02
Tool and fixture making
- 03
Die forging / aluminium forging / hot-padding
- 04
Heat treatment
- 05
CNC machining (milling, turning, drilling)
- 06
Welding
- 07
Assembly of subassemblies
- 08
Testing (tactile, MPI)
- 09
Delivery
Materials & Processes
Aluminium & Aluminium Alloys
High-strength forged lightweight components for chassis solutions from wheel carriers to structural components.
Steel
Base material for heavy forged parts such as crankshafts, steering knuckles and axle components.
Microalloyed Materials
Materials for axle bodies in the hot-padding process; controlled cooling replaces additional heat treatment.
Plastics
Material machined by CNC milling in Daun alongside metal.
Locations
Ennepetal
DEGlobal Holding, CDP steel forge and CDP Railsystems (railway technology)
- Materials
- Steel
- Die forging systems
- CNC machining
Brand-Erbisdorf
DEBharat Forge Aluminiumtechnik – aluminium lightweight forged parts
- Materials
- Aluminium
- Aluminium forging systems
Daun
DETool making, fixture making, CNC machining, metrology
- Lot size
- Small and large series
- Materials
- Steel, aluminium, plastics
- CNC machining centres
- CNC lathes
- Robotic welding systems (MIG/MAG/TIG)
- Coordinate measuring machines (tactile)
Karlskoga
SEBharat Forge Kilsta – heavy steel forged parts (crankshafts, front axle carriers, steering parts)
- Materials
- Steel
- Forging systems
- Heat treatment systems
Industries
Processes & technical limits
| Processes | Tolerance | Max. part | Weight | Lot size | Materials |
|---|---|---|---|---|---|
| Aluminium forging / lightweight forged partsForming | – | – | – | – | Aluminium, Aluminium alloys |
| Steel forging / heavy steel forged partsForming | – | – | – | – | Steel |
| Die forgingForming | – | – | – | – | Steel |
| Hot-padding process (axle bodies)Forming | – | – | – | – | microalloyed steels |
| Heat treatment (post-forging operations)Heat treatment | – | – | – | – | Steel |
| CNC millingMachining | tight tolerances | – | – | Small and large series | Metal, Plastics, Steel, Aluminium |
| CNC turningMachining | – | – | – | Small and large series | Metal, Steel |
| CNC drillingMachining | – | – | – | – | Metal |
| Tool making (forming and follow-on tools)Engineering | – | – | – | – | Metal |
| Fixture makingEngineering | – | – | – | – | Metal, Steel, Aluminium |
| Tactile measurement (coordinate metrology)Testing | Sub-micrometre range | – | – | Single parts, prototypes, series | Steel, Aluminium |
| Assembly of subassembliesAssembly | – | – | – | – | Metal, Steel, Aluminium |
| Automated welding (MIG, MAG, TIG)Joining | – | – | – | – | Steel, Aluminium |
| EngravingMachining | – | – | – | – | Steel, Aluminium, Metals |
| PolishingSurface | – | – | – | – | Metals |
| MPI testing (magnetic particle testing) of lever componentsTesting | – | – | – | – | Steel |
| Corrosion protection (specialised)Surface | – | – | – | – | Steel |
| Machining of carriers, steering levers and mass centring of crankshaftsMachining | – | – | – | – | Steel |
| CAE-based product development / engineeringEngineering | – | – | – | – | Steel, Aluminium |
4 Anlagen & Maschinen
| Machine | Manufacturer / model | Quantity | Working area | Year built | Site |
|---|---|---|---|---|---|
| CNC machining centres | – | – | – | – | Bharat Forge Daun |
| Coordinate measuring machines (tactile, with CNC control / 3D measuring machines) | – | – | Sub-micrometre accuracy | – | Bharat Forge Daun |
| Robotic and automation systems for welding work (MIG, MAG, TIG) | – | – | – | – | Bharat Forge Daun |
| Lathes (CNC) | – | – | – | – | Bharat Forge Daun |
Additional services
Reference customers
Quality & Certifications
Production is carried out under quality management systems certified to IATF 16949 and DIN EN ISO 9001:2015; in Daun, coordinate measuring machines with sub-micrometre accuracy are used, and lever components are inspected by magnetic particle testing (MPI). The company is TISAX-assessed (DEKRA) and a certified partner of Deutsche Bahn (HPQ).
| Evidence | Ennepetal | Brand-Erbisdorf | Daun | Karlskoga |
|---|---|---|---|---|
| IATF 16949 | ||||
| DIN EN ISO 9001:2015 | ||||
| TISAX (VDA ISA) | ||||
| DIN EN ISO 14001:2015 | ||||
| DIN ISO 45001 | ||||
| DIN EN ISO 50001 | ||||
| HPQ (Deutsche Bahn) |
History
- 1646
Foundation of the Kilsta forge in Karlskoga – over 300 years of forging tradition