Analysis and improvement of the most important parameters of industrial metal forming process

Thermal Image from the Forging Process

Storage Area of Forge of Jawor

Forging Being Dropped by the Operator

Overview

This thesis focuses on the critical analysis and optimization of industrial forging processes, with specific emphasis on the automotive industry's production requirements. Forging is a vital method in manufacturing high-quality metal parts, which must meet rigorous standards for durability, efficiency, and cost-effectiveness. The research leverages the Forge of Jawor as a case study to evaluate current practices, identify challenges, and propose innovative solutions.

Objectives

The primary goal of this study was to improve manufacturing efficiency by identifying inefficiencies and potential optimizations within key stages of forging. These include temperature control, material handling, lubrication, die alignment, and quality control. Specific tasks included analyzing existing processes, identifying problems, and proposing solutions grounded in engineering tools and methodologies.

Key Processes Analyzed

Forging Methods:

Upsetting

Open-die forging

Closed-die forging (with and without flash)

Lubrication:

Importance of reducing tool wear and maintaining dimensional accuracy.

Heat Treatment:

Techniques such as annealing, tempering, and normalizing for microstructural optimization.

Automation:

Integration of robotic systems for increased efficiency and precision.

Case Study: Forge of Jawor

The Forge of Jawor, a leading Polish forging facility, provided practical insights into the challenges of producing high-quality forgings. Key operations analyzed included material storage, cutting, forging, trimming, heat treatment, and quality control.

Observed Challenges:

Temperature Control: Inconsistent billet heating caused inefficiencies and defects.

Tool Lubrication: Suboptimal lubrication methods led to tool wear and production delays.

Flash Cutting: Misaligned dies resulted in material defects and increased scrap rates.

Operator Training: High turnover and extensive training periods impacted efficiency.

Proposed Optimizations

Forging Process:

Increase temperature checkpoints and improve calibration.

Employ thermal imaging cameras for non-contact temperature monitoring.

Introduce automated forging stands to minimize human error.

Upgrade lubrication systems for better tool life and precision.

Trimming Process:

Develop mathematical models to predict tool wear and optimize flash reduction.

Use 3D reverse scanning for precise quality assessments.

Implement automated manipulators for consistent material handling.

Impact and Benefits:

Adopting these optimizations would lead to:

Enhanced production efficiency.

Reduced defect rates and scrap material.

Extended tool life and reduced maintenance costs.

Improved product quality and customer satisfaction.

Acknowledgments

This work was guided by expert mentorship and collaboration with the Forge of Jawor, reflecting the synergy between academia and industry in solving real-world manufacturing challenges.

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