Forging technology has undergone continuous development during the past few years.

Thyssenkrupp will build an advanced forging line at its Homburg site in Germany’s Saarland region. The company will invest approximately $90 million in a new 12,000-square-meter facility to produce forged front axles for trucks. The centerpiece of the highly automated and digitized forging line will be a 16,000-ton forging press measuring 32.8 feet (10 meters) high and weighing 1,700 tons. According to thyssenkrupp, the press will produce 360,000 forged components per year and will not be restricted to one product. In addition to front axle systems, the line will be able to produce crankshafts and other forged parts as required.

India’s Bharat Forge Ltd. (Kalyani Group), a manufacturer of heavy-duty diesel crankshafts for commercial vehicles, rolled out its one millionth finish-machined crankshaft in mid-May. Bharat Forge, a long-standing supplier to Daimler AG, produces crankshafts that power Daimler’s heavy-duty engines. The company supplies machined crankshafts for the 13L and 15L engine platforms to Detroit Diesel in the U.S. Additionally, Bharat Forge shares the 13L platform with Daimler’s Mannheim plant in Germany. 

This third article in a series about Germany’s Lightweight Forging Initiative (begun April 2016) focuses on potential weight savings through innovative material selection and forging part and process design. In this segment, potential weight savings on a hybrid vehicle and heavy-duty truck are considered.

Meritor Inc. entered into an agreement with an affiliate of The Carlyle Group, a global investment firm, under which Meritor will acquire AxleTech for approximately $175 million. Troy, Mich.-based AxleTech designs, engineers, manufactures, sells and services drivetrain systems and components, axles and braking solutions. These capabilities will enable Meritor to offer global customers a wider array of differentiated products and solutions while further diversifying its portfolio.

Porsche and Schuler have chosen Halle an der Saale, Germany, as the location for their new joint press shop. The 13-hectare site is in the vicinity of Porsche’s Leipzig plant. The sports-car manufacturer and the forming specialist from Göppingen want to drive the flexibility and digitalization of body-part manufacturing. Their joint venture, Smart Press Shop GmbH & Co. KG, will invest approximately $112 million in this project, which is expected to create 100 permanent jobs. Construction is due to commence in the second half of 2019, and production at the new press shop is scheduled to begin in 2021. 

OSR Inc., a manufacturer of automotive fasteners, plans to increase its manufacturing production in Columbus, Ind. The company, a joint venture between Japan’s Owari Precise Products Co. and Columbus-based Rightway Fasteners Inc., will invest $7 million to construct and equip a new 82,395-square-foot manufacturing facility. OSR plans to add up to 12 new positions and is hiring immediately for positions in heat treatment and IT. Production is scheduled to increase at the beginning of 2020. OSR, which currently has 29 employees, specializes in M4 to M9 cold-forged fasteners, primarily for Toyota.

SMS group received an order from Dongfeng Forging Co., part of commercial vehicle manufacturer Dongfeng Motor Group, for the supply of an eccentric forging press with a forging force of 5,000 tons for its plant in Shiyan, Hubei Province, China. Dongfeng Forging, which operates a total of 26 forging lines at this site, intends to use the new forging press to manufacture light-truck crankshafts with a maximum finished part weight of 47 pounds (21.5 kg). The closed-die press will forge parts fully automatically with a nominal forging force of 50 MN.

Miyake Forging, a Japan-based supplier of hot- and cold-forged bearings and a provider of heat-treating and machining services, opened a new 48,000-square-foot plant in Surgoinsville, Tenn. The facility will produce bearing components for the automotive industry. Miyake Forging already operates two plants in Japan and one in Thailand. The Tennessee venture, the company’s first in the U.S., currently has 14 employees, but employment is expected to increase in the future.

Bharat Forge Ltd. (India) made a strategic investment of approximately $12.9 million in Tevva Motors Ltd. (Chelmsford, U.K.), a supplier of electric powertrain solutions for commercial vehicles and buses. These vehicles actively and autonomously manage the use of the range extender by utilizing Tevva’s patented software, Predictive Range Extender Management System (PREMS), to ensure only electric drive is used in low carbon zones and other city centers. By virtue of this investment, Bharat Forge has also acquired a license for commercialization of the Tevva technology within India and for strengthening its R&D activities in the e-mobility market.