A Critical Comparison of Production Units Used in the Closed-Die Forging Industry

Abstract

The aim of the research project was to identify typical characteristics of the equipment used in the closed-die forging industry and the behaviour of these units in practical conditions. Guidance in making optimum use of equipment has been provided by analysing the factors which directly influence the performance of hammers and presses. From the analysis, a model for the selection of the appropriate unit for minimum cost of a defined quantity of forgings to be produced, could be set up. Preforming methods, and their effect on process efficiency, were also dealt with. Consideration of production alternatives suggests that, in order to achieve optimal utilisation of the equipment available, a new and more flexible type of lay-out should be attempted. A simulation model for production scheduling was created, based on ‘real world' data, rather than on generation of random numbers. An appraisal of precision forging for blades confirmed that there is a unit which is the most appropriate for the purpose. Finally, a real example shows that all the factors involved in a particular forging process play an important part in the selection of the main forging unit.