1. Introduction

Adhvika Forge Tech Pvt Ltd is a leading provider of turnkey solutions in the forging industry, specializing in aluminum alloy forging for automotive, aerospace, and defense applications. The company offers end-to-end services, including machine installation, process development, tooling design, and product manufacturing. This project report outlines the development of Adhvika Forge Tech and its expertise in aluminum alloy forging.

2. Objectives

The main objectives of this project include:

• Developing cost-effective and high-precision aluminum alloy forging processes.
• Setting up advanced forging lines for lightweight automotive and aerospace components.
• Reducing material wastage and improving energy efficiency.
• Offering fully integrated solutions from raw material selection to final machining.

3. Scope of the Project

The project covers the complete development of aluminum alloy forging, including:

• Material selection and procurement
• Tooling design and die manufacturing
• Forging process setup and execution
• Heat treatment and finishing processes
• Quality control and inspection
• Logistics and supply chain management

4. Development of Adhvika Forge Tech

4.1 Company Evolution

Adhvika Forge Tech was established in 2018 as a forging consultancy and later expanded into manufacturing and turnkey project execution. In 2024, the company became a private entity and has since focused on providing innovative forging solutions with a specialization in aluminum alloy forging.

4.2 Facilities and Infrastructure

The company has:

• Head Office in Bangalore.
• Manufacturing Facility in Jamshedpur, Jharkhand.
• In-house facilities for die making, machining, and heat treatment.
• Capability to forge complex aluminum alloy components with high accuracy.

4.3 Expertise and Solutions

Adhvika Forge Tech provides:

• Closed-die forging solutions for aluminum alloy components.
• Automotive lightweighting solutions for fuel efficiency and performance improvement.
• Aerospace-grade forging with high strength-to-weight ratios.
• Electric Screw Press solutions with energy-saving features for precision forging.
• End-to-end project execution, including machine installation, commissioning, and process development.

5. Aluminum Alloy Forging Process

5.1 Material Selection

Aluminum alloys such as 6061, 7075, and 5083 are chosen for their lightweight properties, corrosion resistance, and strength.

5.2 Die Design and Manufacturing

• High-precision dies are designed using CAD/CAM software.
• Advanced CNC machining ensures the accuracy of die cavities.

5.3 Forging Process Setup

• Billet cutting and heating: Aluminum billets are cut to size and heated to forging temperature (~450–500°C).
• Forging operation: The heated billets are shaped using Electric Screw Presses or Hydraulic Presses.
• Trimming and flash removal: Excess material is removed to achieve the final shape.

5.4 Heat Treatment and Surface Finishing

• Solution treatment and aging: The forged parts undergo heat treatment for enhanced mechanical properties.
• Surface finishing: Machining, anodizing, and coating are applied as per customer requirements.

5.5 Quality Control and Testing

• Dimensional inspection using CMM (Coordinate Measuring Machine).
• Non-destructive testing (NDT) for crack detection.
• Hardness and tensile strength tests to ensure compliance with standards.

6. Benefits of Adhvika Forge Tech’s Aluminum Forging Solutions

• Lightweight and high-strength components for automotive and aerospace applications.
• Material savings due to near-net-shape forging.
• Energy-efficient forging with Electric Screw Presses.
• Cost-effective production with optimized cycle times.
• Enhanced durability and resistance to wear and corrosion.

7. Conclusion

Adhvika Forge Tech is at the forefront of aluminum alloy forging, offering cutting-edge solutions for the automotive, aerospace, and defense industries. With state-of-the-art infrastructure, expertise in process development, and a commitment to quality, the company is poised to drive innovation and efficiency in the forging sector.

8. Future Plans

• Expansion of forging capabilities to include titanium and other lightweight alloys.
• Development of fully automated forging lines for mass production.
• Collaboration with global automotive and aerospace OEMs for advanced component manufacturing.
• Adoption of Industry 4.0 technologies for data-driven manufacturing and quality improvement.

Adhvika Forge Tech continues to be a pioneer in forging innovation, providing cost-effective and high-quality solutions for industries worldwide. #adhvikaforgetech