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How can you reduce scrap rate in forging?

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Forging is a manufacturing process that involves shaping metal by applying compressive forces, usually with a hammer or a press. Forging can produce strong and durable parts, but it also generates scrap metal that can reduce the efficiency and profitability of the process. Scrap rate is the percentage of material that is wasted or discarded during forging. Reducing scrap rate can help you save costs, improve quality, and minimize environmental impact. Here are some tips on how you can reduce scrap rate in forging.

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André Cristiano

Engenheiro Mecanico

1 Choose the right material

The type and quality of the material you use for forging can affect the scrap rate. Some materials are more prone to cracking, warping, or oxidation than others. For example, high-carbon steel is harder to forge than low-carbon steel, and aluminum alloys are more sensitive to temperature changes than copper alloys. You should choose a material that suits your product specifications, forging equipment, and operating conditions. You should also ensure that the material is free of defects, impurities, or contaminants that can compromise its performance or appearance.

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André Cristiano

Engenheiro Mecanico
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Muitas vezes o material forjado já vem especificado pelo cliente, como s?o os casos de autope?as, ent?o alterar a matéria prima pode n?o ser uma solu??o viável ou simples, mas é possível especificar materiais específicos para as matrizes de forja evitando desgastes prematuros e consequentemente sucata, tanto da matriz já desgastada, se o projeto n?o permitir retrabalho, assim como de produto forjado que possivelmente possuirá anomalias dimensionais devido desgastes do ferramental de forja.

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2 Optimize the design

The design of the part you want to forge can also influence the scrap rate. You should aim for a design that minimizes the amount of material required, reduces the number of forging operations, and simplifies the shape and geometry of the part. You should also consider the tolerances, dimensions, and surface finish of the part, and avoid features that are difficult or impossible to forge, such as sharp corners, thin walls, or complex curves. You can use software tools, such as CAD or FEA, to help you optimize the design and simulate the forging process.

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André Cristiano

Engenheiro Mecanico
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O projeto do produto acabado possui influências na gera??o de sucata em fun??o de suas próprias especifica??es, como geometria e material, mas o projeto adequado do ferramental de forja considerando volume de material suficiente para suprir as dilata??es térmicas e necessidades de sobre metal para opera??es de usinagens, retificas etc. posteriores s?o fatores importantes para uma expectativa mínima de gera??o de sucata.

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3 Control the temperature

The temperature of the material and the forging equipment is another critical factor that affects the scrap rate. The temperature determines the flow and deformation of the material, as well as the formation of scale and oxide layers. If the temperature is too high, the material can melt, burn, or lose strength. If the temperature is too low, the material can crack, fracture, or harden. You should monitor and regulate the temperature of the furnace, the dies, and the material throughout the forging process. You should also use lubricants, coatings, or protective atmospheres to prevent oxidation and scaling.

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André Cristiano

Engenheiro Mecanico
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Controle de temperatura do material a ser forjado, somado com um controle de carga do martelo da forja (strain gage), permite uma deforma??o/conforma??o de forja mais estável, mais repetitiva, que a depender da geometria do produto acabado qualquer pequena varia??o (decimal) da dimens?o de controle pode acarretar gera??o de sucata por excesso de material (apenas o excedente) ou até mesmo do produto forjado por falta de material.

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4 Maintain the equipment

The condition and performance of the forging equipment can also have an impact on the scrap rate. The equipment includes the furnace, the hammer or press, the dies, and the ancillary devices. You should inspect and clean the equipment regularly, and replace or repair any worn or damaged parts. You should also calibrate and adjust the equipment to ensure that it operates at the optimal speed, pressure, and alignment. You should follow the manufacturer's instructions and safety guidelines, and train your operators to use the equipment properly.

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5 Manage the inventory

The inventory of the material and the parts you forge can also contribute to the scrap rate. You should store the material and the parts in a clean, dry, and secure place, and protect them from moisture, dust, corrosion, or damage. You should also label and track the inventory, and use a FIFO (first in, first out) system to prevent the material and the parts from aging or deteriorating. You should also avoid overstocking or understocking the inventory, and plan your production schedule and demand forecast accordingly.

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6 Here’s what else to consider

This is a space to share examples, stories, or insights that don’t fit into any of the previous sections. What else would you like to add?

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How can you reduce scrap rate in forging?

1

2

3

4

5

6

1 Choose the right material

2 Optimize the design

3 Control the temperature

4 Maintain the equipment

5 Manage the inventory

6 Here’s what else to consider

Mechanical Engineering

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How can you reduce scrap rate in forging?

1

2

3

4

5

6

1 Choose the right material

2 Optimize the design

3 Control the temperature

4 Maintain the equipment

5 Manage the inventory

6 Here’s what else to consider

Mechanical Engineering

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