JG AUTOMOTIVE S.A.

BF 4000 - Hot Former - Forging

JG Automotive is the Bifrangi Group Spanish office founded by Mr. Francesco Biasion, formed by Bifrangi SPA, Bifrangi UK, Bifrangi GMBH and Boltex INC. The Bifrangi Group is a leading global supplier and manufacturer of Hot Former, the HATEBUR BF 4000 being able to forge 1 piece/sec from 200 grams up to 25 kg, mainly flanges and Wheel hubs. These are some examples of the manufacture of metal parts in forging.

Árbol de Levas

Ring Rolling - FORJA

Through Ring Rolling, we can optimize issue weight to make it almost equal to the final weight. Ring Rolling is mainly used for parts with a long interior hole that would mean a considerable loss by other technologies. This way, we can assure great savings by avoiding machining (and losing material) after forging process. In metalworking, rolling is a metal forming process in which metal stock is passed through one or more pairs of rolls to reduce the thickness and to make the thickness uniform with a bigger diametre. Applications of this process could be ball and roll bearing collars, Steel rims of railway wheels, tube belts, pressure recipients, rotary machines,.. Besides material reduction, Ring Rolling allows shaped walls along with mechanical advantages such as hardening through cold process.

upsetter-forging

Through this forging process we can lower manufacturing prices by forging only part of the piece. Unlike previous forging methods that are made by hot processes, this also can be done by cold forging. It consists on accumulating material in a specific and limited area of a piece (usually in bar form). Therefore, a direct consequence of this forging process is that it decreases the length of the initial bar and increases the cross-section thereof in the depressed area. If the process is done by cold forging and at the ends of the pieces it is called cold heading.

Split Forging

We are suppliers and manufacturers of connecting rods forged with Split Forging technology.. Split Forging improves mechanical characteristics of the connecting rods as well as reinforcing the tightening torque of the screws between the head and connecting rod body. This technology (Split Forging) reduces the total production time of the connecting rods because it produces parts ready to separate foot and head directly from the forging process.

Cold forging

JG Automotive is a supplier and manufacturer of metal parts and components developed in cold forging is possible, we reduce substantially the costs comparing to other technologies like: turning, gear carving or hot forging plus mechaning. Cold forging technology is especially recommended for long production series and low weight parts. Customers can choose this technology for a number of reasons: Cold forged parts require little or no finishing work which saves manufacturing costs. It is also less susceptible to contamination problems and the final component has a better overall surface finish. Other benefits of cold forging include: Easier to impart directional properties, improved interchangeability, better reproducibility, greater dimensional control, handle high stresses and high loads and produce net shape or parts of net shape.

Extrusion – Forging

Extrusion forging is an ideal technology to save material and be able to obtain hollow forms not feasible by other forging processes. JG Automotive is a supplier and manufacturer of direct extrusion or reverse extrusion or also indirect, as adapted to the part. Extrusion is a process used to create objects with defined and fixed cross-section. The material is pushed or withdrawn through a die of a desired cross-section. The two main advantages of this process over manufactured processes are the ability to create very complex cross sections with materials that are brittle, because the material only encounters compression and shear forces. In addition the end pieces are formed with excellent surface finish. It can be direct or indirect extrusion. Direct extrusion, also known as front extrusion, is the most common extrusion process. This works by placing the bar in a strongly reinforced container. The bar is pushed through the die by the spindle. There is a reusable dummy block between the spindle and the bar to keep them separate. The major disadvantage of this process is the force required in the extrusion of the bar by the frictional force due to the need for the bar to travel through the container completely. That is why the greatest force required is at the beginning of the process and decreases as the bar is depleted. In indirect extrusion, also known as delayed extrusion, the bar and the container move together while the die is stationary. The die is held in place by a support which should be as long as the container. The maximum length of the extrusion is given by the strength of the column of the carrier. As the bar moves with the container, the friction is eliminated. Advantages: A 25 to 30% reduction in frictional force, allows the extrusion of long bars, there is a less tendency for the extrusion to crack or break because there is no heat formed by the friction, the coating of the container will last longer due to Less use.

Microforging

Microforging is a Japanese technology that allows saving more than 30% on traditional lathes as the piece conforms to the final conditions. Applicable to smaller than 10 grams pieces. Especially suitable for bolts, rivets, axes, clockworks, electronics, …

Multi direcitonal forging

Multi directional Forging is a technology is quite unique as it consists of a forging process that allows two-way stamping, obtaining complex parts and reducing production times and costs.

Forging non-ferrous

We forge other non-ferrous materials like aluminum or brass, saving raw material and increasing mechanical properties according to the needs of our customers. Aluminum forging Forged aluminum parts have much higher mechanical properties than injected aluminum parts, a higher fatigue strength, with the consequent maintenance of mechanical properties over time, under very demanding conditions. In addition, on the pieces obtained by the Forging process, we can make a series of surface finishes impossible to perform with the parts obtained by Injection, as in the case of ceramic coatings. With respect to weight, a piece forged in aluminum has a weight three times inferior to that of a piece of steel Brass Forging The Brass forging or hot stamping consists of deforming a piece of brass rod previously exposed to temperature under pressure of two matrices that give shape. The metallurgical parameters to be taken into account in the stamping are the composition of the brass and the temperature. Depending on the composition of the brass, it acquires certain properties, and influences the mechanical characteristics, plasticity, fusibility and conformability.

MIM

MIM (Metal Injection Molding), as it is fusion by injection, allows reaching tolerances even narrower than investment casting and makes possible to fill intricate geometries better than other casting processes, thus, designers no longer have the traditional limitations when trying to mold stainless steel, nickel – iron, copper, titanium and other metals, although this process has a higher cost. MATERIALS For the process of this technology, we can use a wide variety of metal alloys, such as various steels, titanium, copper, nickel and more are available. JG Automotive can manufacture its precision components in the perfect material for your application. PROCESS MIM merges two established technologies: plastic injection molding and powder metallurgy. MIM technology offers more design freedom than many other production processes.

Investment casting

Thanks to the technology of Investment Casting we obtain pieces of complex geometries, with narrow tolerances and very tight roughnesses without having to rework the piece a posteriori with machining or welding. This contributes to great savings and final finishes of great quality in a single production process. We are specialized in pieces from few grams up to 75 kilos in this technology. The excellent quality of the surface finishing allows us to insert the desired logo or code directly from the mold. Investment Casting allows us to melt any material without changing its mechanical properties. To produce the pieces, wax models are made through the use of molds made of aluminum by machining or EDM, successively placed in appropriate tanks containing thermosetting resins and ceramic microgranules. Both joints polymerize, rising an outer coating resistant to the very high temperatures of the melt metals. In order to minimize the possibility of formation of micorporosities in the foundries, the so-called “Cluster” or “Shell” is introduced inside a high temperature autoclave for the complete evacuation of the residual wax, obtaining a negative mold ready for the following operation. Then, after properly preheating the “Shell” or “Cluster” the melt metal is emptied therein and allowed to cool in a controlled temperature environment to avoid any hardening of the metal. The outer shell will be destroyed and the molten sheets of the fusions will be removed one by one before proceeding to the following machining or surface finishes.

Sintered

Casting by sintered is the heat treatment of a powder or compacted metal or ceramic by pressure with the subsequent passage through a controlled atmosphere oven and at a temperature below the melting temperature of the mixture, approximately 70% -80% thereof. Therefore, it allows increasing the mechanical strength of the piece by increasing the grain size. ADVANTAGES OF SINTERED Purity of the starting materials. Pieces with uniform and controlled porosity. High control in the composition of the material. Pieces are obtained very close to their final shape. Possibility to manufacture parts in virtually any material, including combinations of different materials and ceramic materials.

Grey iron casting

JG Automotive is a supplier and manufacturer of parts, parts and components in Gray cast iron. The gray cast iron is mainly oriented for parts with low mechanical requirements, gray cast iron is a very interesting option given its low cost. It is suitable for short, medium or high series allowing very interesting economies of scale for certain products whose function implies resisting high temperatures or without mechanical purpose. In Gray Foundry, most of the carbon content in gray iron occurs in the form of graphite scales or sheets, which give iron its color and desirable properties. Gray iron is easy to machine, has high tempering ability and good flowability for casting, but is brittle and low tensile strength. Gray iron is widely used in applications such as bases or pedestals for machines, tools, racks for heavy machinery, and cylinder blocks for vehicle engines, brake discs, agricultural tools, stoves, boilers, among others.

Aluminum casting

JG is a supplier and manufacturer of parts, components and parts in cast aluminum. The aluminun casting had its main advantage in the reduction of the weight in 7 times with respect to the steel foundry, although its price is higher. We can provide it either by injection process or gravity or mixed, as well as in processes under high pressure or low pressure. The addition of aluminum quantities over 6.5% removes the graphite in the foundries and causes the matrix formed by ferrite and complex carbides to appear. This ferritic structure such as that of silicon smelters is very stainless and refractory to heat. The two most important classes are: 1. Foundries with 7% aluminum that have good fire resistance and can be used up to 950 ° C They are mechanized quite well. Its tensile strength is about 18 kg / mm2 and its Brinell hardness 300. 2. Castings with more than 8% aluminum which have very good oxidation resistance and can be used at higher temperatures up to about 1000 ° C. They are difficult to machine except the grinding wheel. Its tensile strength is about 13 kg / mm2 and its hardness usually varies from 250 to 500 Brinell.

GGG-70

We are suppliers of castings in GGG-70 and special alloys since 1980. JG Automotive is a benchmark supplier in the steel smelting industry with more than 30 years of experience. Our technology, innovation and a management system adapted to the needs of each client with the intention of offering you the best service and the best price in the production of castings. The main mechanical properties of the GGG-70 material are the hardness and its yield strength. Used mainly for metal and mechanical parts with high wear and high stress loads.

Stainless steels casting

We are suppliers of castings in stainless steels and special alloys since 1980. Stainless steels are very resistant to corrosion (rust due to iron oxide) in many environmental contexts, especially the atmosphere. Chromium is the most important element of the alloy with a minimum content of 11%. The high resistance to corrosion is improved with the addition of Ni and Mo. Stainless steels are classified according to the microstructure: martensitic, ferritic or austenitic. E stainless steel has a wide range of mechanical properties and excellent corrosion resistance makes this type of steel very versatile. Some stainless steels are used in harsh environments at high temperatures because of their resistance to oxidation and mechanical integrity under those conditions that can reach up to ~ 1000 ° C. Gas turbines, steam generators, heat treatment furnaces, aircraft parts, missiles, etc. Are made with these types of stainless steels. JG Automotive is a benchmark supplier in the steel smelting industry with more than 30 years of experience. Our technology, innovation and a management system adapted to the needs of each client with the intention of offering you the best service and the best price in the production of stainless steel castings.

Si-Mo - Casting

Thanks to this casting, we get parts with very high resistance to temperature, such as engine intake pieces. It is a very unique technology since it requires a great level of knowledge and experience by the staff. This technology has a widespread use in automotive. This is achieved due to the following properties of its chemical components: Silicon (Si): Used as a deoxidizing element. It is the fundamental alloying element of the magnetic sheet and that used in electrical applications. Improves resistance to oxidation. Increases hardenability in steels with non-graphitizing elements. Increases strength of low alloy steels. Molybdenum (Mo): Raises the grain growth temperature of austenite. Increases hardenability. It counteracts the fragility of temper. Improves hot strength and increases hot hardness. Increases corrosion resistance in stainless steels. It forms particles resistant to abrasion.

Fine blanking (Estampación)

Fine Blanking: allows much higher results mainly in Dimensional Tolerance; Flatness of the piece; Quality of cutting finish (cut without tearing). Fine blanking parts are characterized by extremely precise, rectangular crack and tear-free cut surfaces. These precision parts are manufactured with the tightest tolerances, great angular accuracy and the best possible flatness. A complex design is possible through the integration of different forming processes in the tool. The metal stamping consists of a process of machining without starting of shaving where the steel sheet is cut by means of presses for the achievement of certain metallic pieces. For this in the presses the dies are placed with the necessary operations. The basic elements of a die are the punch having the shape and dimensions of the hole to be made, and the cutting die whereby the die is inserted when it is forcefully driven by the power provided by the press through a Eccentric drive that generates a dry and forceful blow on the sheet, producing a clean cut of the same.

Progressive Stamping

Home Progressive Stamping Progressive Stamping Progressive Stamping: It allows very low costs producing parts in a very efficient way but with high cost of tools. The metal stamping consists of a process of machining without starting of shaving where the steel sheet is cut by means of presses for the achievement of certain metallic pieces. For this in the presses the dies are placed with the necessary operations. The basic elements of a die are the punch having the shape and dimensions of the hole to be made, and the cutting die whereby the die is inserted when it is forcefully driven by the power provided by the press through a Eccentric drive that generates a dry and forceful blow on the sheet, producing a clean cut of the same.

Manual Stamping

Manual Stamping: The part price is high but has very low tooling costs. The metal stamping consists of a process of machining without starting of shaving where the steel sheet is cut by means of presses for the achievement of certain metallic pieces. For this in the presses the dies are placed with the necessary operations. The basic elements of a die are the punch having the shape and dimensions of the hole to be made, and the cutting die whereby the die is inserted when it is forcefully driven by the power provided by the press through a Eccentric drive that generates a dry and forceful blow on the sheet, producing a clean cut of the same

Mechanical-weld assemblies - LASER MIMAR

JG Automotive manufactures mechanical-welded assemblies, providing different technologies for their manufacture, from Engineering to laser cutting, welding, bending, folding, punching, cold sealing, painting and assembly, depending on the needs of the set of parts. Precision welding We have complete welding stations with groups to weld with TIG – MIG – MAG, pulsed arc, plasma and spot welding and welding robots capable of welding large series in short times. Our solutions include certified welders as WPS, PQR and WPQR procedures. Laser Cut Laser cutting of Steel, Stainless Steel and Aluminum in thicknesses from 0.5 to 25mm. We have machines up to 4 meters. Punching Punching and forming of parts using the latest CNC technologies with the highest precision. Punching of parts up to 6 meters. Bending and Folding We fold pieces up to 5 meters. We can work with all types of profiles, thicknesses and metals, making the different types of folding according to the characteristics of the material: Bottom folding, Partial folding and Coining. Surface Treatment We offer surface treatments of epoxy-polyester powder paint, zinc plated, galvanized, anodized, blued, geomet, etc. collaborating with a wide range of suppliers, so that the piece is ready for assembly. Industrial liquid paint for metal parts We are specialists in industrial liquid paint for metal parts. To produce coatings we use liquid paint technology, which allows us to meet the highest technical demands against corrosion. We work under high quality standards, which leads us to obtain an optimal coating result in each and every one of the pieces that enter our factory. Cold Sealing Technology to join metal parts using high-strength gluing products, providing a better finish and significant weight reduction. Set Assembly We provide solutions for the assembly of the whole, in a precision process to carry out high-level finishes.

High-Pressure Cylinders

JG Automotive is a manager in the manufacture and supply of high pressure cylinders without hydrogen welding. We manufacture high pressure Hydrogen cylinders to provide solutions to hydrogen filling stations. Read more JG Automotive is the Commercial and Technical Headquarters in Spain and Portugal of EUROCYLINDER SYSTEMS AG Apolda (Germany), producing high pressure cilynders without the following particulars: Range of external diameter in millimeters: 83 to 267 Capacity range in L: 0.74 to 80.0 Pressure test in bar: 250 to 450 – 60 for acetylene High pressure steel bottles are used for the storage and transportation of compressed, liquefied and dissolved gas. Our bottles are made with convex or concave bases. According to customer request, bottles may be required with foot, collar, valve and valve protection. It is also possible to deliver the full bottles. We have stock of bottles in Spain with capacity for valve assembly, repainting and certified revalidation.

MIM

G Automotive is the commercial office of Indo-MIM in Spain, world leader manufacturer and supplier of Metal Injection Moulding casting parts and components. MIM Technology, as it is fusion by injection, allows reaching tolerances even narrower than investment casting and makes possible to fill intricate geometries better than other casting processes, thus, designers no longer have the traditional limitations when trying to mold stainless steel, nickel – iron, copper, titanium and other metals, although this process has a higher cost. MATERIALS For Metal injection molding process, we can use a wide variety of metal alloys, such as various steels, titanium, copper, nickel and more are available. JG Automotive can manufacture its precision components in the perfect material for your application. PROCESS This technology merges two established technologies: plastic injection molding and powder metallurgy. MIM technology offers more desing freedom than many other production processes.

Precision Machining

JG supplier and manager in the manufacture of machined metal parts and components in various types of machining for the industrial and automotive sector. Machining is a manufacturing process which comprises a set of parts forming operations by removing material, either by chip removal or by abrasion. It is made from semi-finished products such as bars. Profiles or other parts previously shaped by other processes such as casting or forging. The products obtained may be final or semi-processed which require further operations. The machining of parts and components can start a bar with chip removal (Bar turning) and different materials such as steel machining and aluminum in addition to other more specific materials. Type of Machining: - 5 axes - Multi-spindle - Transfer - CNC 4 meters - Dedicated Lines

Aluminum and Steel Extrusion

JG Automotive is supplier and manager in the manufacture of components of aluminum and steel extrusion, mainly focused on parts and components in the transport sector: automotive, bus and rail. The term “extrusion” is usually applied both to the process and to the product obtained when a hot cylindrical ingot of aluminum (called billet) passes through a matrix with the appropriate shape (direct extrusion or forward). The resulting profile can be used in long stretches, or it can be cut for use in structures, vehicles or components. Extruded Products represent more than 50% of the European aluminum products market; of this percentage, the building sector uses most of it. In addition, extruded aluminum is also used in the transport of cargoes, in aircraft fuselages, road vehicles railways, and marine applications. The versatility of the extrusion process in terms of the number of alloys and possible shapes makes it one of the most valuable elements when it comes to allowing the aluminum profile manufacturer to offer customers solutions for their design needs. The most common products made by extrusion are: Tubes, structural profiles and for frames, rods, rails, joints, plates, seat rails and rings for engines. THE ADVANTAGES OF ALUMINUM IN THE BODYWORK OF VEHICLES 1- Good resistance to fire and arc of resistance. 2- Fuel savings. Savings of 6% in consumption. 3- High performance in shock absorption. It can absorb resistance between 55-60% compared to steel. 4- Low emission and longer useful life. 1kg Aluminum equals 2 kg of steel. 5- Recyclable. Scrap aluminum reaches a value of about $ 1,550 / Ton. Around 75% of aluminum is recycled in the earth. 6- All the weight of the vehicle is lighter, reducing in a 10% the weight of a steel body. The benefits that aluminum achieves with respect to steel are mainly: the simplicity of the structure, lower cost, lighter, easy to assemble and easy to repair.

Springs and metal forming

JG Automotive, is Scherdel Group Sales and Service Office (SSO) for Spanish and Portuguese market. Scherdel is one of the world leaders in the design and manufacture of springs and cold formed parts. Scherdel Group offers a wide portfolio of products and services, including: technical springs, piston rings, inlet and exhaust valve springs, cold formed and stamped parts, clamps, fine-blanking, assembled subassemblies, welded seat structures, Metal-plastic components, design of assembly processes, design and manufacture of production machinery, as well as surface treatments in its own facilities. An enormous capacity of designs adapted to technical specifications of every application, in the fields of: Automotive, Medical equipment, Electronic equipment, Electrical mobility, Design of Tools and machinery for the assembly processes. Scherdel offers its clients a wide knowledge in Research and Development (R&D) of components and manufacturing systems, improving and optimizing the design of each component and its manufacturing process, thus ensuring the quality and performance of the components manufactured. SCHERDEL is developing parts and assemblies for hybrid and purely electric units and produces them in mass(e-Mobility). They can be found in electrical machines, power electronics and energy storage systems. Metal and plastic composite materials are also used, such as laser-welded products made of highly purified copper. Scherdel has more than 125 years of history with continuous growth and a long-term commitment to its customers and collaborators, with a presence in 29 countries worldwide, allowing it to be considered a global company. TYPES OF SPRINGS: – Compression – Disc – Tension – Constant force and power spring – Piston ring – Seal ring – Spiral – Valve – Wave

Precision gears

PRECISION GEARS MANUFACTURED WITH COLD FORGING JG Automotive is the commercial office of O-OKA in Spain, world leader in cold forging precision, specialists in the manufacture of gears of high level of design and complexity for the automotive sector. Innovating in the concept of technology and improving the conventional machining process, we introduce the forging technique and develop a new possibility in gear technology. INCREÍBLE MEJORA DE LA RESISTENCIA: APLICANDO LA FORJA The comparative results of the gear resistance made at the University of Aachen, Germany Approx. 50% improvement in fatigue resistance has been confirmed by comparative tests of fatigue Ooka forged gears and conventional machining gears. Since the flow line is kept (not cut), forging ensures higher strength compared to machining. Shift feeling is significantly increased Gears formed by Ooka’s precision forging technology provides a better shift feeling, We have received tremendous favor from our customers. Compact transmission design Integrating the clutch gear and the main gear body into one piece, enables a substantial compactness and weight reduction of the transmission. Furthermore, forging of recessed gear design creates the innovative impact. Cutting-edge quality in production processes O-oka complies and is certified with TS16949 international Quality Management system in the automotive industry. At the same time O-oka has established quality system that suits any customer requirment in the world. O-oka is not only certified ISO14001/2004 but strives and supports the clean-plant policy of forging industry.

Bearings

JG Automotive wants to offer our Customers a complete Catalogue with more than 3,000 references of friction elements for radial and / axial support: ball, roller, cylindrical, spherical and taper roller bearings, shaft, tensioners and idlers, manufactured upon TS16949 certification and installed in millions within leading Automotive and Industrial Prime Companies. JG Automotive is glad to present a full range of economical and robust solutions, suitable for different applications for Tourism vehicles, Commercial vehicles, Trucks, Buses, Tractors, Agriculture machinery and Industrial applications (train, nautical, eolic, aeronautical sectors): Clutch Release Bearings, Bogie-Suspension Bearings, Steering columns, Gear Boxes, Pumps, Vibration devices, Mast guides, others, to grant quality and a simpler installation.

Tubes

JG Automotive is supplier and manager in the manufacture of metal parts and components, is able to supply tubes in any material (metallic) and with processes of production adapted to the needs of the client among which we emphasize: ERW TUBE – Electric – Resistance Welded Tubes CDW TUBE – Cold Drawn – Welded Tubes SEAMLESS TUBE STAINLEES STEEL TUBE JG automotive is a specialist in the manufacture of tubes of different types, mainly for the automotive sector such as: - Round tube - Square tube - Rectangle tube - Galvanized tube - Exagonal tube - Carbon steel tube - Copper tube - Pipe joints - Common-rail systems - Bundy Tubes

Fasteners

JG Automotive supplies and distributes Fasteners in medium and long series, made with high quality materials with rigorous quality controls. JG has its approved partners, for the manufacture and production of them. We carry out exhaustive inspections and controls from the base to the different types of finishes and coating. We have a connection with international manufacturers, which allows us to offer a wide range of products.

Horquillas Maquinaria Agrícola

Mecanizado Agrícola

Mecanizado Agrícola

Mecanizado Agrícola

Mecanizado Automoción

Mecanizado Automoción

Mecanizado Automoción

Mecanizado Automoción

Mecanizado Automoción

Mecanizado Automoción

Mecanizado Automoción

Mecanizado Automoción

Mecanizado Automoción

Mecanizado Automoción

Mecanizado Automoción

Mecanizado Hidráulico

Mecanizado Hidráulico

Mecanizado Hidráulico

Mecanizado Hidráulico

Mecanizado Hidráulico

Mecanizado Industrial

Mecanizado Industrial

Mecanizado Industrial

Mecanizado Industrial

Mecanizado Industrial

Inspección soldadura en línea sin ensayos destructivos

Using a control algorithm, we enable the automated inspection process to be monitored, detecting discontinuities or unwanted events. Several parameters are analyzed simultaneously, eliminating the need to cut parts because we can already be certain that the welding process was successful.

Visual inspection based on IA through algorythm that detects any kind of defect

Using proprietary algorithms, visual defects are translated into formulas, enabling the software to detect any defect visible to the human eye, even with magnetic particle inspection. It is not an image-comparison system, so from just a few images—dozens, to be exact—the system can be trained to detect multiple defects in a production line, with moving parts, and any type of defect in any material. It is even suitable for monitoring assembly sequences and other tasks performed by an online inspector.