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Forging

FEATURE ARTICLES | 2024-08-15

Clean Steel Standards and Optimizing Gear Design

Gears serve as essential mechanisms in a wide range of mechanical equipment, helping to transmit torque, adjust rotational speeds, transfer power, distribute load and more. Used in necessary applications such as automobiles, energy systems, aerospace and industrial equipment, gears must be able to operate for long periods without maintenance. While gears can be made from a diverse assortment of materials, carbon and alloy steel offer superior benefits in terms of strength, durability and cost efficiency. As a remarkably recyclable material, steel may also be a preferable choice for environmentally conscious manufacturers.

INDUSTRY NEWS | 2024-08-06

Role of Forging in Supply Chain Resilience

The success of manufacturing critical components, such as ship shafts, gears, artillery or adaptor plates/rings, depends on their design and how well that design can be translated into a tangible, cost-effective, high-quality product. This is where Design for Manufacturability (DFM) comes into play. The significance of DFM rests in the forging process's role in creating a robust and resilient supply chain.

FEATURE ARTICLES | 2024-04-09

Forging Ahead

Specialty forgers can manufacture custom, high-quality, seamless rolled rings in a variety of materials and finishes in as little as eight weeks. Open die forgings and seamless rolled rings are essential components in the wind energy sector, contributing to the overall reliability and efficiency of turbines, generator systems, and transmission and distribution equipment.

EVENT | 2024-03-13

AISTech 2024

With 100+ technical sessions and more than 300+ individual presentations, AISTech attendees can plan their day around the conference schedule and learn about the latest products and processes happening in every aspect of the steelmaking process. Sessions include safety/health, environmental technology, cokemaking, ironmaking, sheet rolling, metallurgy, MRO, lubrication, material handling and more. Join this steel industry event in Columbus, OH from May 6-9, 2024, at the Greater Columbus Convention Center.

INDUSTRY NEWS | 2023-07-25

A Look Back at Forge Fair 2023

The Forging Industry Association’s (FIA) Forge Fair, North America’s largest event dedicated exclusively to the forging industry, returned to the Huntington Convention Center in Cleveland, Ohio, May 23–25, 2023. More than 2,000 forging professionals from across the globe attended Forge Fair to learn about new products, make purchasing decisions, and network with each other. This specialized-industry event offered suppliers and forgers a platform to connect with more qualified potential customers. From material selection to the shipment of finished parts, Forge Fair showcased innovations in heating, tooling, equipment, testing, automation, conservation of resources, process and plant improvements, and technology for all types of forging operations.

EVENT | 2022-05-05

International Forging Congress 2022

The International Forging Congress (IFC) is a global event that brings together key players from the international forging community to exchange information and experiences. IFC features forging industry technical and business-oriented presentations. In addition, exhibitors display their forging-related products and services to IFC attendees.

GEAR TALK WITH CHUCK | 2020-07-24

Help Wanted

Northwest Pennsylvania’s Oil Region has a long history in manufacturing. Many of the widgets that made oil extraction and processing possible were ...
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FEATURE ARTICLES | 2020-07-01

Supply Chain Management Users Guide

We asked a few industry suppliers to provide some insight into gear manufacturers' supply chain challenges during the pandemic.
GEAR TALK WITH CHUCK | 2019-09-26

Thoughts on Team Building

The last post suggested constructing a fighting robot machine as a team building exercise. As a sole proprietor for the last eleven years, I am a b...
INDUSTRY NEWS | 2019-06-12

Oelheld Introduces Forging Lubricants

Oelheld recently announced a line of forging lubricants at Forge Fair 2019. The company is also a proud member of the Forging Industry As...
GEAR TALK WITH CHUCK | 2019-01-30

From Co-op to Vice President: Octave A. LaBath

I was attending the University of Cincinnati in the college of engineering. After my freshman year in 1960, I started my co-op job with the Cincinn...
TECHNICAL ARTICLES | 2018-01-01

Globalization's Effect Upon Gear Steel Quality

Background on the development of a high-speed, automatic hardness tester for gear steels.
FEATURE ARTICLES | 2018-01-01

Holding Fast, Bouncing Back

Business is finally starting to get back to usual in the big gear world, which offers us a chance to look back at the greatest lesson on how to survive an economic downturn. Includes the sidebar: "Brass Tacks with Klingelnberg."
FEATURE ARTICLES | 2017-11-01

Material Assets

You get one shot to make a first impression. One opportunity to show your customers, vendors and suppliers that you provide a steady, reliable product that will generate repeat business. How do you make this happen? What tools and strategies are available to get gear materials (forgings, gear blanks, etc.) shipped faster and more efficiently in today's tech-heavy, fast-paced, manufacturing environment?
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GEAR TALK WITH CHUCK | 2015-11-19

The Importance of Prompt No Quotes

Before going on an extended blog series on my “points system” for evaluating business opportunities, I want to talk about the importance of issuing...
GEAR TALK WITH CHUCK | 2015-11-03

The Task No One Enjoys

What task has to be done at every gear shop that no one enjoys? If you’ve followed this blog with any regularity you know how much I admire the uns...
GEAR TALK WITH CHUCK | 2015-07-30

New Ways to Make Old Parts

My last post discussed reviewing the ratings and designs of “legacy products,” those venerable parts and gearboxes still being ordered twenty, thir...
GEAR TALK WITH CHUCK | 2015-06-04

Things We Don’t Know

Noted gear consultant and gear educator Ray Drago is fond of saying that a consultant’s best answers usually start with “it depends.” Those of you ...
FEATURE ARTICLES | 2015-03-01

Solving the Forgings Paradox

The process of forging metal into shapes possesses a surprisingly long and storied history. For example, the method of hot rolling can trace its protracted existence all the way back to an enigmatic Italian polymath named Leonardo da Vinci (you may have heard of him), who reportedly invented the rolling mill one lazy day in the 1400s.
GEAR TALK WITH CHUCK | 2014-05-01

So How Much is This Going to Cost?

[starbox] Estimating is a necessary evil in every shop. Nobody wants to do it, but if it doesn’t get done there is no business. Fortunately, we ...
INDUSTRY NEWS | 2013-09-10

Eaton Brings Forging Operation In-House

Diversified industrial manufacturer Eaton has announced that its South Bend, Indiana, facility has added a $1.9 million cross-wedge-rolli...
TECHNICAL ARTICLES | 2012-10-01

Differential Gears

What are the manufacturing methods used to make bevel gears used in automotive differentials?
TECHNICAL ARTICLES | 2008-05-01

Manufacturing Net-Shaped, Cold-Formed Gears

A net-shaped metal forming process has been developed for manufacturing quality, durable, high-yield and cost-efficient gears for high-volume production.
INDUSTRY NEWS | 2006-01-19

Metaldyne Purchases Forging Technologies

Metaldyne announced its purchase agreement with Forging Technologies Inc. related to the acquisition of Metaldyne's North American fo...
TECHNICAL ARTICLES | 2002-01-01

Net-Shape Forged Gears - The State of the Art

Traditionally, high-quality gears are cut to shape from forged blanks. Great accuracy can be obtained through shaving and grinding of tooth forms, enhancing the power capacity, life and quietness of geared power transmissions. In the 1950s, a process was developed for forging gears with teeth that requires little or no metal to be removed to achieve final geometry. The initial process development was undertaken in Germany for the manufacture of bevel gears for automobile differentials and was stimulated by the lack of available gear cutting equipment at that time. Later attention has turned to the forging of spur and helical gears, which are more difficult to form due to the radial disposition of their teeth compared with bevel gears. The main driver of these developments, in common with most component manufacturing, is cost. Forming gears rather than cutting them results in increased yield from raw material and also can increase productivity. Forging gears is therefore of greater advantage for large batch quantities, such as required by the automotive industry.
TECHNICAL ARTICLES | 2000-05-01

A Modular Approach to Computing Spiral Bevel Gears and Curvic Couplings

In general, bevel gears and curvic couplings are completely different elements. Bevel gears rotate on nonintersecting axis with a ratio based on the number of teeth. Curvic couplings work like a clutch (Fig. 1).
FEATURE ARTICLES | 1998-07-01

Alternative Gear Manufacturing

the gear industry is awash in manufacturing technologies that promise to eliminate waste by producing gears in near-net shape, cut production and labor costs and permit gear designers greater freedom in materials. These methods can be broken down into the following categories: alternative ways to cut, alternative ways to form and new, exotic alternatives. Some are new, some are old and some are simply amazing.
TECHNICAL ARTICLES | 1995-07-01

How to Avoid Errors When Measuring Step Gears

There are problems in dimensional measurement that should be simple to solve with standard measuring procedures, but aren't. In such cases, using accepted practices may result in errors of hundreds of microns without any warning that something is wrong.
TECHNICAL ARTICLES | 1995-05-01

Long-Life, Low-cost, Near-Net-Shape forged Gears

Near-net gear forging today is producing longer life gears at significantly lower costs than traditional manufacturing techniques. Advances in forging equipment, controls and die-making capability have been combined to produce commercially viable near-net-shape gears in diameters up to 17" with minimum stock allowances. These forged gears require only minimal finishing to meet part tolerance specifications.
TECHNICAL ARTICLES | 1992-05-01

Gear Blanking

The term "blanking" refers to the initial metal cutting operations in the process planning sequence which produce the contour of a part starting from rough material. The scope of blanking is: To remove the excess material To machine the part to print specifications, except for those surfaces with subsequent finishing operations. To leave adequate machining stock for finishing operations. To prepare good quality surfaces for location and clamping of the part throughout the process.
TECHNICAL ARTICLES | 1990-07-01

Manufacturing of Forged and Extruded Gears

Traditional methods of manufacturing precision gears usually employ either hobbing or shaper cutting. Both of these processes rely upon generating the conjugate tooth form by moving the work-piece in a precise relation to the tool. Recently, attention has been given to forming gear teeth in a single step. Advantages to such a process include reduced production time, material savings, and improved performance characteristics. Drawbacks include complicated tool designs, non-uniformity of gears produced throughout the life of the tooling, and lengthy development times.
TECHNICAL ARTICLES | 1985-01-01

Computer Aided Design (CAD) of Forging and Extrusion Dies for the Production of Gears by Forming

Material losses and long production times are two areas of conventional spur and helical gear manufacturing in which improvements can be made. Metalforming processes have been considered for manufacturing spur and helical gears, but these are costly due to the development times necessary for each new part design. Through a project funded by the U.S. Army Tank - Automotive Command, Battelle's Columbus Division has developed a technique for designing spur and helical gear forging and extrusion dies using computer aided techniques.
TECHNICAL ARTICLES | 1984-08-01

Precision Forged Spiral Bevel Gears

A recent U.S. Army Tank-Automotive Command project, conducted by Battelle's Columbus Laboratories. successfully developed the methodology of CAD/CAM procedures for manufacturing dies (via EDM) for forging spiral bevel gears. Further, it demonstrated that precision forging of spiral bevel gears is a practical production technique. Although no detailed economic evaluation was made in this study, it is expected that precision forging offers an attractive alternative to the costly gear cutting operations for producing spiral bevel gears.
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