When it comes to forging research, it turns out that size really does matter. The bigger the press, the lower the chance of using it for experimentation and the higher the costs associated with the research.

The COVID-19 pandemic has changed the forging landscape –seemingly overnight. With many in the industry initially expecting the impact to last a matter of weeks, most forgers are now preparing for a much longer recovery period that will likely last into early 2021.

In the manufacturing world, many people use technology readiness as a means of describing the journey within the valley of death, the gap between proof of concept and first use in the operational environment.

Germany’s Kaiser Aluminium-Umformtechnik GmbH, a manufacturer of forged-aluminum components for small- and medium-sized products, successfully started up its first Schuler servo screw press. The system will be primarily used to produce complex chassis components for the automotive industry. The investment further expands Kaiser Aluminium-Umformtechnik’s market position as a competent partner for forged parts and components in the aluminum sector.

France’s Transvalor, a manufacturing process-modeling software developer, joined the University of Strathclyde’s (Scotland) Advanced Forming Research Centre (AFRC) as a tier-one partner. The first partner to join the AFRC in support of its soon-to-be-opened FutureForge facility, Transvalor will provide process simulation expertise and deep insight into material behavior resulting from manufacturing processes. The FutureForge facility will help manufacturing companies of all sizes become more competitive by exploring less energy-intensive methods of forging. It will also use digital technologies to accelerate the development of forged products.

SMS group put a 31.5/34-MN open-die forging press into operation at Gustav Grimm Edelstahlwerk (GGE), a forge based in Remscheid, Germany. GGE specializes in the manufacture of high-alloy forgings. Because of the built-in hydraulic and control systems, GGE’s new high-speed forging press achieves time savings of about 10% compared to the old press. For the first time, SMS group has installed an additively manufactured machine component in an open-die forging press. The 3D-printed hydraulic manifold block is lighter, more compact and has a flow-optimized design. Designed by SMS group and made of an aluminum alloy, it weighs just one-tenth of the conventional steel component. The manifold block is used to distribute hydraulic oil for operating and venting the cylinders.

For millennia, a sword was a warrior’s weapon of choice. Forged by a blacksmith heating metal or a combination of metals and working it into shape, the best swords for winning battles were not the sharpest or the longest, they were the strongest, most hard-wearing ones.

Italy’s Danieli Group (Danieli Breda) recently commissioned a new integrated forging complex at the Zlatoust Metallurgical Plant (ZMZ) in Chelyabinsk region, Russia. The plant consists of a 25-MN open-die forging press and two integrated manipulators operating in conjunction with Danieli’s proprietary DanForge automation system. The open-die press has 80-spm frequency, a daylight span of nearly 11.5 feet, automatic top-die clamping and an automatic tool-changing device. The manipulators can lift ingots weighing 20 tons with a load moment of 60 t/m.

In an era where equipment is routinely rendered obsolete at an ever-increasing pace, forging equipment stands alone as machines built to work on a daily basis for decades – if not the better part of a century.

For decades, automotive component makers have relied on hot forging presses and shearing systems to transform metal bars into high-quality parts such as drive shafts, gear wheels and bearing rings, to name but a few.