Even the most advanced automobile or aircraft relies on thousands of small moving parts, such as discs, sleeves, rings, cylinders, and shafts. Historically, these parts have been produced via casting or machining methods, but new innovations in cold forging techniques have led to the process of near-net shape forging.
By producing small parts and components that come in a nearly complete state with state-of-the-art industrial computers, manufacturers can enjoy faster production times and lower operating costs.
What is Near-Net Shape Forging?
Machine shops and major manufacturers often require forged components for various applications, such as custom solutions, small-quantity runs, or roles that require high strength and durability. Typically, these companies contact forging specialists to produce components “as forged,” meaning they come in the correct shape and material specifications but must be further machined to get the proper tolerances, dimensions, and surface finishes. In other words, they order a partially finished product and perfect it themselves.
However, perfecting these “as forged” components is costly in terms of both time and money. “As forged” components typically have coarse surface finishes, metal scales, and uneven surfaces that need to be machined away. This increases production costs, accelerates tool wear, and takes up man-hours of work, all of which reduces overall profitability.
Near-net shape forging avoids this by producing components as close as possible to their finished state, or “net shape.” Whether by open or closed die forging, metal is repeatedly hammered and stamped into the desired shape. This is in contrast to casting, where molten metal is poured or injected into the mold to achieve the desired shape.
Forging’s greatest advantage over casting is that the hammering process ensures metallurgical integrity by producing a certain grain flow. This means the “grains” within the metal run along the length of the material or object, which makes it more resilient against tensile and shear loads. This is an incredibly important factor for meeting safety and reliability standards, which is why forged components are almost always preferred over cast equivalents.
Benefits of Near-Net Shape Forging
Near-net shape forging comes with multiple benefits over other manufacturing methods, including:
- Shorter Production Time: By reducing the amount of post-forging machining needed to have parts ready, companies can get their products ready faster.
- Lower Costs: By using less resources and energy and requiring fewer man-hours to complete parts, companies ultimately save money when compared to other production methods.
- Less Waste: As a form of lean manufacturing, near-net shape forging uses fewer raw materials and produces less scrap than other production methods, which reduces overall waste.
- Increased Metallurgical Strength: As previously mentioned, forged metal parts boast superior resilience compared to cast components.
What Does Near-Net Shape Forging Require?
Like any other advanced technology or technique, near-net shape forging requires support from other technologies, such as:
- CNC Machines: Computer Numerical Control (CNC) machines are a cornerstone for modern manufacturing and machining processes. These machines can precisely shape, hammer, and press metal into the correct shape and dimensions.
- Virtual Simulations: With virtual simulations like digital twins, companies can analyze the shape of a component and the materials used in its construction to predict its effectiveness. This helps reduce the need for expensive prototypes and accelerates the testing and development process.
- Industrial Computers: Reliable and powerful industrial-grade PCs are critical for effectively controlling CNC machines and simulating how the finished product will function in working conditions. Whether they are industrial panel PCs or rugged mini PCs, these computers must be powerful enough to support industrial applications and resilient enough to handle harsh working conditions.
- Artificial Intelligence: AI can enhance all of the above categories, leading to more efficient automation, more accurate simulations, and more powerful industrial edge AI box PCs that can manage an entire machine shop with a single device.
Achieve Near-Net Shape Forging with Cybernet Industrial Computers
With near-net shape forging, manufacturers and machinists can achieve higher-quality products at lower costs than other manufacturing techniques. If your business is looking for a partner that can supply powerful and reliable industrial computers to support your forging, contact the team at Cybernet Manufacturing. We’d be happy to explore how our pre-built models can support your efforts or collaborate on a custom solution.