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CONTENTS
A.EXECUTIVE SUMMARY
B. THE IMPORTANCE OF THE FORGING INDUSTRY
BACKGROUND
Role in manufacturing
Markets/Metals/Applications
BASIC FORGING PROCESSES
Impression-Die (hot, cold, warm); Open-Die; Ring Rolling
BRIEF HISTORY
Origins
Contraction of the 1980s
THE INDUSTRY TODAY
Number of Units/Plant Size/Distribution
C. A VISION FOR THE FORGING INDUSTRY OF THE FUTURE
Preferred process/World leader
Safe/clean/automated
Strategy/measure performance/customer partners
Virtual enterprise/exchange information with manufacturing chain
Global marketing strategy
Eliminate hazardous waste
Skilled workforce/Profession of choice
Profitability through productivity
D. KEY COMPETITIVE CHALLENGES
Technology development and application
find and deploy strategically significant technologies
die design/modeling
Energy and the environment
energy efficient/environmentally responsible
cooperate to make process environmental asset
pollution prevention
reduce or eliminate forging die lubrication
reduce energy consumption
induction heating/combustion advancements
waste treatment/recycling
renewable energy and environmental protection
Cooperative efforts
leverage resources/share knowledge/protect IPRs
enlist suppliers/fair compensation at each stage
information exchange/technology deployment
Unify support for Industry Vision
Competitiveness
process improvement + productivity = profitability
electronic product design/process technology
net-shape/materials utilization
decrease per-unit energy, die, and labor costs
uniform standards for electronic commerce
Education
customers
basic skills of workforce
generate political/legislative support
new information exchange/teaching technologies
new forging technologies
specific action
Markets
meet customers' future needs
changes in existing markets
globalization/realistic projections for demand
new products/markets
value-added services
competing materials/processes
emerging technologies
global market opportunities
Human resources
reestablish an improved public perception
rewards based on performance
drive education/consider trends affecting workforce
management staff/strategies
E. STRATEGIC TARGETS
Tooling, Energy, Material utilization, Productivity, Quality, Environment
F. CONCLUSION
APPENDIX A--FORGING INDUSTRY NEEDS
Forging Industry
Vision of the Future
A. EXECUTIVE SUMMARY
The forging industry is a key link between critical manufacturing segments--metal
suppliers (both ferrous and nonferrous) and end user industries. Forgings, which
appear in 20% of the products representing the Gross Domestic Product of the
United States, are essential to the U.S. industrial economy, to its society, and to
its national security.
In recent years the U.S. forging industry has undergone significant shrinkage
associated with intense global competition, technological changes, and
environmental and economic factors. Those companies that survived the industry
downsizing emerged stronger, better equipped to face the competitive challenges
of manufacturing today--escalating demands from customers, changing markets,
global competition, and threats from competing manufacturing processes.
The forging industry of today looks forward to the year 2020 with an awareness
of the business and technical challenges that will shape its future. The major
forces shaping the business community of the future are:
Increasing globalization of markets.
Demand for a greater return on investment and increased capital
productivity.
Customer expectations for increasingly higher levels of quality at a lower
price.
Changing skill requirements of industry employees.
In the year 2020, forging will be the cost-effective, preferred process by which
metal components of superior quality, integrity, and performance are produced for
critical and demanding applications. The U.S. forging industry will be the world
leader in materials development and utilization, process application, energy
management and efficiency, environmental responsibility, and effective utilization
of human resources. Industry-wide cooperation and collaborative efforts between
forging companies, suppliers, universities, and government laboratories, will
enable the U.S. forging industry to maximize its resources in the development
and application of advanced technology.
In order to meet the competitive challenges of the future and achieve its vision,
the forging industry must fortify itself in several critical areas: technology
development and application; energy and the environment; cooperative efforts;
competitiveness; education; markets; and human resources.
Specific areas in which technological issues need to be addressed include
materials, die design and modeling, lubrication, process modeling and
optimization software, process controls and sensors, real-time preventative
maintenance, and primary and secondary processing equipment.
The forging industry of the future will be energy efficient and will protect the
environment. Environmentally acceptable, functionally effective, and affordable
technologies are needed that integrate pollution prevention into the entire metal
forging processing system design.
Cooperative research will play a major role in returning the U.S. forging industry
to world leadership. Forging companies must leverage their limited resources by
teaming with customers, suppliers, government, academia, and other forgers to
locate the significant technologies that are being practiced or are under
development.
To achieve the industry's vision of the future, forgers must pursue dramatic
forging process breakthroughs--looking at the end product and radically changing
the existing process to produce parts that satisfy the customer, while providing a
reasonable level of profitability for all parties in the supply chain.
A multi-pronged strategy of ongoing education is key to the forging industry's
ability to attain its vision. The forging industry will take an active role in educating
from several inches to over 20 feet in diameter. Rings can range in weight from
one pound to more than 50,000 pounds, and are typically used in gears,
bearings, couplings, rotor spacers, and components for pressure vessels and
valves.
HISTORY
Forging is the oldest known metal working process, dating back to the days when
prehistoric peoples learned to heat sponge iron and beat it with a stone to form a
useful implement. Modern forging is a science that developed from the ancient
art practiced by the armor makers and the immortalized village blacksmith.
Sophisticated, high-powered hammers and mechanical presses now replace the
strong arm, the hammer, and the anvil, and modern metallurgical knowledge
supplements the art and skill of the craftsman in controlling the heating and
handling of the metal.
Historically, forging has relied on the skill of the operator. The manufacture of
forgings still depends on people, but advances in equipment and process control
technology are rapidly changing the nature of jobs and skills required in the forge
shop.
Technological improvements in forging processes provide substantial advantages
over other competing manufacturing processes, such as higher strength, superior
internal integrity, more consistent and higher metallurgical properties.
Sophisticated control systems and advanced processing equipment permit
forgers to produce products with greater uniformity, to extremely tight
dimensional tolerances, in time to meet customers' stringent delivery schedules,
thus adding to the inherent benefits of the forging process.
Throughout the 1980s the forging industry underwent a painful contraction due to
over capacity and pressures from world markets. The deep recession of the early
1980s shrank forging end-user markets, weakening many forging companies.
The reduced competitiveness of the U.S. forging industry was compounded by
import penetration. Between 1979 and 1990, an estimated 25% of the
commercial forging industry was forced out of business. The closing of more than
100 forging facilities caused a loss of more than 16,000 jobs.
In some cases, the industry has fragmented into smaller firms that have difficulty
investing in capital intensive up-to-date equipment, and in sustaining a strong
research and development program. In other cases it consolidated into larger
companies.
Those companies that survived the industry downsizing emerged stronger, better
equipped to face the competitive challenges of manufacturing today--escalating
demands from customers, changing markets, global competition, and
threats from competing manufacturing processes.
THE INDUSTRY TODAY
According to trade press estimates, in 1995 there were approximately 450
facilities at which the forging process is performed in the United States. More
than half of these are located in five States: Ohio, Pennsylvania, Illinois,
Michigan, and California. Another 20% of the nation's forge shops are in Texas,
New York, Indiana, Wisconsin, and Tennessee.
through higher productivity, shorter lead times, and superior quality near-net or
net-shape products.
D. KEY COMPETITIVE CHALLENGES
In order to meet the competitive challenges of the future and achieve its vision,
the forging industry must fortify itself in several critical areas. The key challenges
that must be addressed by the industry fall into the following categories:
Technology development and application.
Energy and the environment.
Cooperative efforts.
Competitiveness.
Education.
Markets.
Human resources.
TECHNOLOGY
The industry needs to develop and put in place programs and systems to help
find the strategically significant technologies--already in practice, that have been
developed, or are being developed--and find ways to deploy those technologies
to the industry. Cooperative industry efforts on the forge process will make the
forging industry world leaders in bulk deformation.
The forging industry must lead the drive for technological advances that benefit
many facets of the forging process, and continue to enhance the industry's
competitiveness and profitability. Specific areas in which technological issues
need to be addressed include materials, die design and modeling, lubrication,
process modeling and optimization software, process controls and sensors, realtime preventative maintenance, and primary and secondary processing
equipment. Other research and development needs for the forging industry are
outlined in Appendix A.
New lighter-weight, higher-strength, and higher-quality alloys will be
needed to compete with alternative materials and processes and make
forgings the components of choice.
Tooling material technology advancements must focus on developing
more reliable, longer-lasting die materials.
Surface modifications of the die-material interface are becoming
increasingly important.
Die design and modeling software will supplement metallurgical
improvements, adding at least an order of magnitude to the life of tooling.
Advanced rapid prototyping technology will be incorporated into forged
product design and engineering processes. This will serve customers by
speeding the time it takes to go from concept to finished part.
Advanced computer models must improve product and process efficiency
to satisfy the time, cost, and quality demands of customers in the future.
Powerful computer codes that are accessible to every forging company
are needed to quickly and accurately model material flow during the
forging process and predict forged product microstructure and mechanical
properties.
Advanced process controls and sensors must monitor all aspects of the
forging process. Forging plants of the future need to incorporate such
systems that completely integrate the manufacturing process so that each
operation will automatically sense and compensate for process variations
in other operations. Through careful design these processing systems
must incorporate great stability and flexibility.
New, more reliable and predictable equipment must be developed to suit
this unique forging process while improving material utilization and
producing the near-net and net-shape parts that satisfy the future needs of
the industry's customers.
Advanced raw materials shearing systems will optimize processing
parameters by automatically compensating for variations in raw material
thickness or cross section, producing a cut workpiece of constant volume.
Advancements in electrical resistance, electrical induction, and fossil-fuel
heating technologies will promote energy efficiency in the forging industry.
New, "smart" forging presses and other pre- and post-forging equipment
are needed to improve utilization of energy, raw materials, and labor. They
must facilitate efficient and capable of monitoring and correcting the
forging deformation process on a real-time basis for the economic
production of net- and near-net-shape forgings.
New technologically advanced processes, procedures, and devices will
permit single-minute changeover, making one-piece work flow
economically feasible for families of parts.
Advanced lubricants will yield incremental progress toward an
environmentally benign process, that increases die life, process efficiency
and improves product quality, reliability, and predictability.
ENERGY & ENVIRONMENT
The forging industry of the future will be energy efficient and will protect the
environment. In the 21st Century, the forging plant will be a zero environmental
liability, making it a valued and responsible neighbor in its community and a
respected source of high-paying jobs for workers in the surrounding area.
To attain the vision, cooperative efforts within the forging industry must maximize
the financial resources for research projects and technology development that
focus on making the process an environmental asset.
Technologies are needed that integrate pollution prevention into the entire metal
forging processing system design. These technologies must be environmentally
acceptable, functionally effective, and affordable. The following programs will
address these issues and significantly impact the forging industry:
Eliminate aerosol emission within the plant through the use of advanced
die systems. The development of cost-effective new production methods
(such as net shape forging) will eliminate the need for post-forging
removal of surface material.
Establish a program that develops and deploys environmentally benign
lubricants, or eliminates the requirement for die lubrication altogether.
year 2020, and anticipate and effect the changes forgers must make in order to
meet those needs.
Changes in existing major markets (such as automotive, aerospace, power
generation, railroad, marine, construction and off-highway, industrial, etc.) will
significantly affect customer demand and opportunity for use of forgings. The
forging industry's future success will be shaped by the kinds of products its
customers will be producing and the metal components that will be required.
The trend toward globalization of the marketplace will continue to escalate,
resulting in competitive challenges and market opportunities. As a whole, the
industry must identify and evaluate the variables and indicators that will allow it to
make realistic projections for the use of forgings in the U.S. and throughout the
world. This process must accurately identify and assess:
existing customers whose future needs will offer increased opportunities
for the forging industry, as well as those whose demand for forgings will
decrease;
new target products and markets for forgings;
new or improved services that add to the value of forgings for the
customer;
existing competitive materials (metal matrix composites, ceramics,
plastics)
existing competitive processes (powder metallurgy, casting, stamping,
fabricating)
emerging technologies, such as semi-solid forming
competitive global market opportunities.
To assure profitability in the 21st Century, the industry must develop a clear
picture of world-wide forging capacity and size of the global market. This analysis
must include an assessment of existing foreign competitors, as well as realistic
estimates of the potential competition from forging capabilities that will emerge in
third-world and other developing countries.
HUMAN RESOURCES
Human resources are among the most important keys to the future success of
forging enterprises.
Forging companies must structure their organizations to encourage, reward, and
make it desirable for engineers in all disciplines to work on their plant floors. This
must be a cultural change to an environment supportive of technology, creating
an opportunity for career advancement for technically qualified employees within
their company.
To attract and retain a top quality workforce, the industry will adopt programs and
practices that will reestablish the public perception of forging as a respected,
noble, and safe profession.
Advances in processing technology, environmental systems, communications
technology, ergonomic programs, and management strategies that reward
employees based on their contribution to company performance will make the
forging plant of the future a desirable place to work.
To reach its vision, the forging industry must establish programs and
mechanisms that drive the public and private education systems to develop
The greatest potential for progress toward achieving the Forging Industry Vision
of the Future is to leverage the forging industry's limited R&D resources through
partnerships between forging companies, industry organizations (FIA and
FIERF), customers, suppliers, academic institutions, and federal laboratories.
Developing and deploying technologies that cut across several "vision" industry
groups will maximize return on American manufacturing's R&D investment.
APPENDIX A FORGING INDUSTRY NEEDS
PRODUCTION EFFICIENCY
Neural networks for process control and optimization.
Modeling and verification of complex problems in metal forging.
Rapid prototyping: tools and manufacturing.
Advanced die materials and surface modifications or coatings.
Advanced contact and non-contact sensors.
Imaging system for commercial quality control and inspection of parts.
Knowledge-based system for troubleshooting industrial equipment.
Develop design relevant material properties.
Training and education.
ENERGY EFFICIENCY
Reduction in heating cycles.
Energy efficient gas fueled burners for furnaces.
Fuel/combustion system optimization.
Advanced cogeneration/waste heat utilization systems.
Induction heating system with reshapable coils.
Model for increasing metal plasticity at lower forging temperatures.
RECYCLING
Energy/environmental life cycle assessment.
Develop economic methods to convert scale to usable products.
ISO 14000 compliance.
ENVIRONMENTAL PROTECTION
Waste stream identification.
Air emissions measurement, reduction, and control.
Water processing and reuses.
Environmental modeling of the forging process.