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Robotics & Market Insights
Forging robots: Where and how to automate metal forming operations?
19 November 2024
Forging robots are enhancing the metal casting industry by automating high-force, precision tasks. We explore the key automation opportunities in forging, their benefits and challenges, and how to get started.
Robotic systems and automated processes can significantly improve forging operations’ precision, consistency, and workplace safety while reducing operational costs and material waste.The growing adoption of these technologies is reflected in market projections, with some analysts expecting the global foundry and forging robots market to grow at a Compound Annual Growth Rate (CAGR) of 6.8% between 2024 and 2030. This trend underscores the increasing recognition of automation's value in addressing key industry challenges such as labor shortages, quality consistency, and competitive pressures.
As automation continues to evolve, which areas of forging operations stand to benefit the most, and what should decision-makers consider when exploring these technologies?
Key Automation Opportunities in Forging
Robotic Press Tending in Forging Operations
Automated robotic systems have become a key component in forging operations, managing critical tasks like moving materials and tending parts to the forging press. Robots essentially mirror the role of a human operator—placing parts into the press quickly and safely before the press completes the forging.
Robotic solutions typically involve high-payload arms equipped with specialized end-of-arm tooling to accommodate the part sizes and shapes as well as their temperature. Separate from this, automated die-change systems can be integrated with the press itself, further streamlining the workflow, though they are not part of the robotic system.
One of the biggest challenges in robotic press tending is managing extremely hot parts. If a robot is tasked with handling heated materials, it must be equipped with grippers designed for high-temperature conditions, and the robot’s structure must also be protected against extreme heat exposure. This type of setup requires specialized integrators with a good understanding of both programming and the environmental demands of forging, as this application can be more complex than other robotic operations.
The main benefits of robotic press tending include increased production speed, reduced labor costs, and improved worker safety by limiting human exposure to heavy loads and high temperatures. By automating these tasks, manufacturers can achieve more efficient and reliable forging operations, leading to higher productivity and better overall performance.
Heat Treatment and Cooling
Automated heat treatment and cooling systems streamline the post-forging process, ensuring consistent material properties and reducing cycle times.
Solutions in this area range from robotic systems for part transfer between heating and cooling stations to fully automated heat treatment cells. Many use temperature sensors and precise timing controls to manage the heat treatment process with high accuracy.
One of the main benefits is the ability to reallocate employees from basic part transfers to more value-added tasks while the robotic system handles part handling. Another benefit is improved cycle time and optimized wait time between heat treatment steps.
Key challenges involve managing the high temperatures involved and ensuring proper handling of parts at various stages of the heat treatment process.
Trimming and Finishing
Automation in trimming and finishing processes can significantly improve product consistency, quality and reduce labor-intensive tasks.
Robotic systems for trimming, grinding, and polishing are increasingly common, as are automated inspection systems using machine vision for quality control.
These systems offer benefits such as consistent finishing quality, rapid and objective inspection, and the ability to handle repetitive tasks without fatigue.
Challenges in this area often relate to having the programming knowledge needed to adapt the cell for different part geometries. Another challenge is ensuring that automated systems can match the adaptability of skilled human workers for complex finishing tasks.
Robots can be used for a range of finishing processes such as deburring.
Common Challenges in Implementing Forging Automation
While robotics and automation offer numerous benefits, forging operations often face several significant challenges during implementation.
The high initial costs associated with advanced robotic systems and necessary infrastructure upgrades can be a substantial barrier, particularly for smaller forging shops operating on tight budgets. This financial hurdle often requires careful planning and may necessitate a phased approach to automation implementation.
Integration with existing processes and equipment presents another complex challenge. Forging operations typically have well-established workflows and legacy equipment that may not easily interface with new automation technologies. This integration process often requires careful planning and can potentially disrupt ongoing operations, leading to temporary productivity losses that must be managed carefully.
Workforce adaptation is a critical yet often underestimated challenge. Successfully implementing automation requires not only training existing staff to work alongside and maintain new systems but also potentially hiring specialists with expertise in robotics and automated systems.
Ensuring flexibility to handle product variety and changes in demand is another significant hurdle. Forging operations often deal with a diverse range of products and fluctuating order volumes. Automated systems need to be adaptable enough to handle this variability without requiring constant reprogramming or adjustment, which can be a complex and ongoing challenge.
Key Considerations Before Automating Forging Operations
Before investing in automation, forging operations should carefully evaluate several crucial factors to ensure successful implementation and maximize returns.
A thorough analysis of current processes is an essential first step. This evaluation helps identify the areas where automation can have the most significant impact, whether in terms of productivity gains, quality improvements, or cost reductions. Understanding the intricacies of existing workflows also helps in selecting automation solutions that can seamlessly integrate into the forging operation.
When evaluating the return on investment, it's important to look beyond simple cost savings calculations. While reduced labor costs are often a primary consideration, it's equally important to factor in potential quality improvements, increased production capacity, and new business opportunities that automation might enable. This comprehensive approach to ROI assessment provides a more accurate picture of the long-term value of automation investments.
The scalability and flexibility of potential automation solutions are critical considerations in an industry where product demands can change rapidly. Forging operations should look for systems that can adapt to future needs, whether that involves handling different types of parts or scaling up production volumes.
The impact on the workforce should be carefully considered and planned for. This includes developing comprehensive training programs for existing staff and considering how roles within the forging operation might change with the introduction of automation. Engaging employees early in the automation journey can help smooth the transition and uncover valuable insights from those most familiar with current processes.
Finally, prioritize safety enhancements and ensure compliance with industry standards and regulations. Automation can significantly improve workplace safety, but only if systems are properly designed and implemented with safety as a primary consideration. This involves not only selecting equipment with robust safety features but also redesigning workflows to maximize the safety benefits of automation.
Where to Get Help and Find the Right Forging Automation Solutions
Navigating the complexities of forging automation can be challenging, but you don't have to go it alone. HowToRobot offers expert guidance to help you make informed choices about implementing automation in your forging operations. Our automation and robotics specialists provide vendor-independent advice, and through our platform, we can connect you with a network of vetted automation suppliers, ensuring you find the right solutions for your needs.
→ Looking for vendor-independent expert advice? Explore our advisory services and connect with us to discuss your forging automation needs. Our experts can help you determine if automation makes sense technically and financially for your specific applications.
→ Ready to find the right automation solutions? Share your project details with us. We'll help you scope requirements, connect with vetted automation suppliers, and receive a range of custom offers. This approach lets you compare different solutions and find the best fit for your needs and budget, often within weeks.
Whether you're looking to automate a specific forging process or implement comprehensive automation solutions, HowToRobot can assist in scoping your requirements, comparing different options, and connecting you with suitable suppliers. By leveraging our expertise, you can streamline your journey towards efficient, automated forging operations.
