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.

Indiana Wheel Corp. (IWC), a manufacturing company specializing in the production and distribution of steel wheels, plans to establish operations in Plymouth, Ind., and create up to 117 new jobs over the next few years. The company, which is a joint venture led by China’s Jingu Company Ltd., will invest approximately $23 million to purchase, renovate and equip a 300,000-square-foot production facility in Plymouth. The plant will include more than $14.5 million of specially designed equipment to support IWC’s manufacturing operations for the trailer and RV industries. Upgrades will begin this summer with production expected to start later this year.

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.

Hydro will upgrade casting operations at its Husnes (Norway) facility with new technology to produce more advanced products for the growing automotive aluminum forging market. Newly developed in-house casting technology, low-pressure casting (LPC), will enable Hydro to provide materials with enhanced properties for various extrusion markets in which it is already a major material supplier. After the upgrade, Hydro Husnes will also be able to offer materials for forging. The Hydro-developed technology enables a shift from traditional extruded forge stock to cast forge stock, eliminating costly steps in the production process while improving quality. The as-cast surface is ready for forging, and homogenizing is not required. The upgraded facility will commence operations in 2020.

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.