Forgers weigh options such as repair, rebuild, remanufacture or new equipment when considering options to increase capacity. This article considers the four options and the pros and cons associated with each.
October 7, 2019
When forges need to expand production to meet increased demand for existing parts or to add new product lines, selecting from available options to bring new equipment online can be challenging.
Cross-wedge rolling (CWR) is a forging technique in which a heated billet is formed by rolling it between two flat (or cylindrical parallel-axis) die plates. This article describes the CWR process and equipment as applied to the production of railroad screws and other similar products.
A recent company survey indicates that forgers are more concerned with the availability of qualified labor than its cost. Given that, the forging community should consider automation to minimize its labor requirements. Automated billet feeding is one area that can improve manufacturing efficiency and reduce labor costs.
North Carolina Governor Roy Cooper announced that Bharat Forge America Inc. will build an aluminum forging plant to manufacture automobile components in Lee County, N.C. The $127.3 million investment will create 304 jobs. The new facility will be part of a larger manufacturing center that will create as many as 460 jobs. According to Bharat Forge, the investment will help it create a strong global manufacturing footprint as part of its aluminum strategy.
Demanding environments in forges require engineered floor systems to accommodate heavy handling equipment in high-traffic areas and impact loading. They also must have thermal resistance to high-temperature workpieces. Various flooring options are available in today’s market, and the selection of appropriate flooring materials is critical to long-term facility goals.
The selection of an appropriate flooring system contributes to increased productivity and profitability by decreasing outages related to floor repairs and replacement, reducing expensive equipment repairs related to inconsistencies in the flooring and decreasing the risk of operator safety concerns and fatigue.
Forgital, a producer of large forged and machined components for the aerospace and other industries, will be acquired by global investment firm The Carlyle Group. The transaction values Forgital at approximately $1.1 billion and is expected to be completed in the second half of 2019. Established in 1873 with headquarters in Vicenza, Italy, Forgital is a specialist in the manufacture of machine-finished forged and laminated rolled rings made from different materials, including steel, aluminum, titanium and nickel-based alloys. In addition to aerospace applications, Forgital also serves the oil-and-gas, construction, mining and power-generation industries. The company employs over 1,100 people across nine facilities in Italy, France and the United States and through its global salesforce.
Allegheny Technologies Inc. (ATI) agreed to sell two non-core forging facilities to Wynnchurch Capital for $37 million. These facilities, located in Portland, Ind., and Lebanon, Ky., are part of ATI’s High Performance Materials & Components (HPMC) segment. They use primarily traditional forging methods to produce carbon-steel forged products for use in the oil and gas, transportation, construction and mining industries. Their capabilities include comprehensive forging processes complemented by in-house design and engineering, product machining and heat-treating services.
The productivity of a forge shop can be greatly affected by the efficient flow of workpieces through the plant. Solutions to handle workflow range from motorized manipulators to rail-mounted systems to overhead manipulators. For most applications there is more than one solution, and an experienced engineer can help you select the right system for your operation. It is important not to be guided by price alone but rather to think in the long term.
Check out the October 2019 issue of FORGE, featuring our cover story that showcases "2019 Buyers Guide. Other features include "Why Forgers Should Invest in Automation", "Flat Tool Cross-Wedge Rolling", and much more.