At SAE-SMB Industries in Charleville-Mézières, France, quality and precision are the cornerstones of axle and suspension component manufacturing. This commitment to excellence was evident during our recent visit, where Adrian Burlan, the Plant Director, guided us through the intricate processes that contribute to the company’s reputation for high-quality products.
SAE-SMB Industries is deeply committed to environmental sustainability. Since 2020, the plant has reduced its energy consumption by 20% to 30%, reflecting its dedication to energy savings and CO2 reduction. “We focus on energy savings and CO2 reduction, with waste materials recycled and chemical by-products managed by specialized disposal companies,” Adrian explained. The facility’s efforts to minimize its environmental footprint also include the responsible recycling of waste materials and strict adherence to local environmental regulations for chemical disposal.
The Manufacturing Journey: The manufacturing process at SAE-SMB begins with the careful selection of raw tubes, chosen based on the specific load capacity requirements of the axles. “We start with raw tubes of varying thicknesses depending on the axle’s load capacity,” he shared. These tubes are then cut to precise lengths and undergo shot blasting to remove impurities before advancing to the forging phase. In the forging area, the tubes ends are heated to approximately 1,200 degrees Celsius, a process that is tightly controlled to ensure each tube reaches the exact temperature required for shaping. “Our heating process is highly controlled to ensure each tube reaches the exact temperature required for shaping,” Adrian highlighted. This step is crucial in producing spindles that offer the necessary flexibility for various axle lengths and track widths. The forging process, which eliminates the need for welding, results in a seamless axle body that enhances rigidity and tensile strength. “By using advanced molds and rolling methods, we can control both the external and internal shapes of the spindles precisely,” he elaborated, ensuring that potential weaknesses from welding are eliminated.The plant’s forging equipment is highly automated, with settings adjusted according to the spindle’s dimensions and thickness. Each forging cycle takes between 95 and 105 seconds. Despite the equipment’s high capacity, the plant operates below its full potential due to commercial constraints. “Currently, our primary focus is on expanding the commercial side. We have the capacity to produce more, and we’re eager to meet the growing demand as order volumes increase.” Adrian candidly admitted.
Machining and Production Process: Once the axle bodies are forged, they proceed to the machining area, where precision is paramount. The rough axle bodies are machined using a primary machine that handles almost all rigid axles. This machine works on both spindles simultaneously, ensuring perfect concentricity and alignment between the spindles and the axle. “The machine processes approximately 5.5 beams per hour with a cycle time of eleven minutes per axle on both sides,” informed Adrian. The machined axle lengths range from 1.8 meters to 3.1 meters, depending on the requirements. After machining, each axle body undergoes a thorough inspection by the operator, who also labels the spindle with their identification number for traceability. In addition to the primary machining process, the plant has a secondary machining sector that handles special products like steering and pendle axles, which require different processing due to their shorter lengths and specific requirements.
