| Dr. Peter
Angelini Project Manager, Advanced Materials Oak Ridge National Laboratory Mr. John Bellanti Director, Manufacturing Engineering American Axle and Manufacturing Mr. Nick Cerwin Director of Technical Sales A. Finkl & Sons Mr. Joe Cipriani President Keystone Forging Co. Mr. Charles Crout Vice President Forging Developments International Mr. Tim Dunagan Group Director, Marketing The Ajax Manufacturing Company Mr. Don Farley Director of Marketing Forging Industry Association Mr. Charles Hageman Executive Vice President Forging Industry Association Mr. Fred Infield Vice President, Engr. & Technology Erie Press Systems Dr. Ramesh Jain Program Manager U.S. Department of Energy Mr. David Kuhlmann Engineering Manager Eaton Corporation Mr. Jim Mazzoli Quality Control Manager Gulf Coast Machine & Supply Company Mr. Frank Mocilnikar H.R. Team Leader SIFCO Forge Group Mr. Thomas Oberg Die Shop Manager Cooper Tools/Forged Products Operation Mr. Michael Pearce Manufacturing Manager Keystone Forging Co. Mr. Gerald Radack Principal Computer Scientist Concurrent Technologies Corporation Mr. Blair A. Shingledecker Chief Metallurgist Milwaukee Forge Dr. Charles Sorrell Program Manager U.S. Department of Energy Mr. Mike Stephens Sr. Manufacturing Engineer American Axle & Manufacturing, Inc Mr. Jacek Swider Engineering Manager Aluminum Precision Products, Inc. Ms. Karen Taylor Director, Membership Development Forging Industry Association Mr. Eric Vrsansky Manager, Axle Manufacturing |
Mr.
Kerry Barnett Director, Defense Sector National Center for Manufacturing Science Mr. Jorge Cardenas Engineering Manager ERISA Mr. Mike Chiesa Sr. Member, Technical Staff Sandia National Laboratories Mr. John Cozzi Vice President, Manufacturing Modern Drop Forge Co. Dr. Sara Dillich Program Manager U.S. Department of Energy Mr. Kenneth Eakin Product Metallurgist Elwood Quality Steels Mr. Philip Guichelaar Professor, Dept. Mech. & Aeronautical Eng. Western Michigan University Mr. Ted Huxford Program Manager Oak Ridge National Laboratory Mr. Robin Ingols Director of Marketing Components Erie Forge and Steel Mr. Robert Krysiak Vice President, Rolled Ring Prod. Scot Forge Co. Mr. Paul Lavins President & CEO American Induction Heating Mr. George Mochnal Director of Research & Development Forging Industry Association Mr. Robert Noel Vice President, Quality & Technology Ladish Company, Inc. Mr. R. B. Omo Manager Engineering Chambersburg Engineering Company Mr. William Peschel Corporate Technical Director American Induction Heating Mr. Jim Sharp Manager, Corporate Environmental Wyman-Gordon Company Mr. Hudson Smith Chairman SIFCO Forge Group Mr. Robert Steimer Manager Technical Services FirstMiss Steel, Inc. Mr. Paul Sturm Sales Manager Lasco Forming Technology Mr. Robert Swope Exec. V.P., Advance Technology Masco Tech Inc. Mr. Algirdas Underys Director, Technology & Development A. Finkl & Sons Co. MascoTech Forming Technologies |
Agenda
| Time | Activity | Organizer | Location |
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| 10:00 - 10:30 AM | REGISTRATION FIA/FIERF | Foyer to Dallas Room | |
| 10:30 - 11:45 PM |
|
Hall of Cities:
Dallas Room |
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| Welcome & Overview | Sara Dillich, U.S. Department of Energy
George Mochnal, FIA/FIERF Robert Noel, Ladish Co., Inc. John Bellanti, American Axle & Manufacturing, Inc. |
||
| Instructions | Jack Eisenhauer, Energetics, Inc. | ||
| 11:45 - 12:45 PM |
|
Kona Kai | |
| 1:00 - 5:00 PM | BREAKOUT SESSIONS
(includes in-room breaks) |
Jack Eisenhauer, Energetics | Assigned Meeting Rooms |
| 6:30 - 8:30 PM | RECEPTION AND DINNER | Banquet Room | |
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| 7:30 - 8:00 AM` |
|
Dallas Room | |
| 8:00 - 8:15 AM | Review and Instructions | Jack Eisenhauer, Energetics | Dallas Room |
| 8:20 - 10:30 AM | BREAKOUT SESSIONS | Jack Eisenhauer, Energetics | Assigned Meeting Rooms |
| 10:45 - 12:00 PM | SUMMARY SESSION | Dallas Room | |
| 12:00 - 1:00 PM |
|
Kona Kai | |
| 1:00 - 2:00 PM | SUMMARY SESSION (contd.)/
CLOSING REMARKS |
Dallas Room | |
| 2:00 PM |
|
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Air-lift hammer - A type of gravity-drop hammer in which the ram is raised for each stroke by an air cylinder. Because the length of stroke can be controlled, ram velocity and therefore the energy delivered to the workpiece can be varied. See also Drop hammer and Gravity hammer.
Bar - A section hot rolled from a billet to a form, such as round, hexagonal, octagonal, square, or rectangular, with sharp or rounded comers or edges, with a cross-sectional area of less than 16 sq in. (A solid section that is long in relation to its cross-sectional dimensions, having a completely symmetrical cross section and whose width or greatest distance between parallel faces is 3/8". or more).
Billet - A semifinished, cogged, hot-rolled, or continuous-cast metal product of uniform section, usually rectangular with radiused corners. Billets are relatively larger than bars. See Bloom.
Blank - Raw material or forging stock (also called a "slug" or "multiple") from which a forging is made.
Blast cleaning - A process for cleaning or finishing metal objects by use of an air jet or centrifugal wheel that propels abrasive particles (grit, sand, or shot) against the surfaces of the workpiece at high velocity.
Bloom - A semifinished product of square, rectangular, or even round cross section, hot rolled, or forged. For steel, the width of a bloom is not more than twice the thickness, and the cross sectional area is usually not less than about 36 sq. In. No invariable rule prevails for distinguishing between blooms and billets; the terms are frequently used interchangeably.
Board hammer - A type of gravity drop hammer where wood boards attached to the ram are raised vertically by action of contrarotating rolls, then released. Energy for forging is obtained by the mass and velocity for the freely falling ram and the attached upper die. See also Drop hammer.
Cast (proof) - Any reproduction of a die cavity in any material, frequently lead, plaster or epoxy, used to confirm the exactness of the cavity. See Die proof.
Cavity, die - The machined recess in a die that gives the forging its shape.
Cleaning - The process of removing scale, oxides, or lubricant--acquired during heating for forging or heat treating--from the surface of the forging. (See also Blasting, Pickling, Tumbling.)
Closed die forging - The shaping of hot metal completely within the walls or cavities of two dies that come together to enclose the workpiece on all sides. The impression for the forging can be entirely in either die or divided between the top and bottom dies. Impression-die forging, often used interchangeably with the term closed-die forging, refers to a closed-die operation in which the dies contain a provision for controlling the flow of excess material, or flash, that is generated. By contrast, in flashless forging, the material is deformed in a cavity that allows little or no escape of excess material. See Impression die forging.
Cold forging - Various forging processes conducted at or near ambient temperatures to produce metal components to close tolerances and net shape. These include bending, cold drawing, cold heading, coining, extrusion (forward or backward), punching, thread rolling and others.
Cold working - Permanent plastic deformation of a metal at a temperature below its recrystallization point--low enough to produce strain hardening. Usually, but not necessarily, conducted at room temperature. Also referred to as cold forming or cold forging. Contrast with hot working.
Die impression - The portion of the die surface that shapes the forging.
Die lubricant - A material sprayed, swabbed, or otherwise applied during forging to reduce friction and/or provide thermal insulation between the workpiece and the dies. Lubricants also facilitate release of the part from the dies and provide thermal insulation. See also Lubricant.
Die proof (cast) - A casting of the die impression made to confirm the exactness of the impression.
Dies (die blocks) - The metal blocks into which forging impressions are machined and from which forgings are produced.
Dies, forging - Forms for the making of forgings; generally consist of a top and bottom die. The simplest will form a completed forging in a single impression; the most complex, made up of several die inserts, may have a number of impressions for the progressive working of complicated shapes. Forging dies are usually in pairs, with part of the impression in one of the blocks and the balance of the impression in the other block.
Drop forging - A forging made in closed or impression dies under a drop or steam hammer.
Drop hammer - A term generally applied to forging hammers wherein energy for forging is provided by gravity, steam, or compressed air. See also Air-lift hammer, Board hammer, Steam hammer.
Efficiency (forging) - The amount of applied energy, in percentage, that is employed in deforming the workpiece to the total energy expended by the forging equipment.
Extrusion - The process of forcing metal to flow through a die orifice in the same direction in which energy is being applied (forward extrusion); or in the reverse direction (backward extrusion), in which case the metal usually follows the contour of the punch or moving forming tool. The extrusion principle is used in many impression die forging applications.
Finish - (1) The forging operation in which the part is forged into its final shape in the finish die. If only one finish operation is scheduled to be performed in the finish die, this operation will be identified simply as finish; first, second, or third finish designations are so termed when one or more finish operations are to be performed in the same finish die. (2) The surface condition of a forging after machining. (3) The material machined off the surface of a forging to produce the finish machine component.
Flat die forging (open die forging) - Forging worked between flat or simple contour dies by repeated strokes and manipulation of the workpiece. Also known as "hand" or "smith" forging. See Open die forging.
Flow stress - A measure of materials resistance to deformation and depends upon such things as temperature and strain rate.
Forging - The process of working metal to a desired shape by impact or pressure in hammers, forging machines (upsetters), presses, rolls, and related forming equipment.
Forging dies - Forms for making forgings; they generally consist of a top and bottom die. The simplest will form a completed forging in a single impression; the most complex, consisting of several die inserts, may have a number of impressions for the progressive working of complicated shapes. Forging dies are usually in pairs, with part of the impression in one of the blocks and the rest of the impression in the other block.
Forging reduction - Ratio of the cross-sectional areas before and after forging; sometimes refers to percentage reduction in thickness.
Fracture toughness - The resistance of a given material to catastrophic failure in the presence of an existing sharp crack.
Friction factor - A factor that, when multiplied by the flow stress, expresses the friction shear stress.
Gravity hammer - A class of forging hammer wherein energy for forging is obtained by the mass and velocity of a freely falling ram and the attached upper die. Examples are board hammers and air-lift hammers.
Hammer - A machine that applies a sharp blow to the work area through the fall of a ram onto an anvil. The ram can be driven by gravity or power. See also Gravity hammer and Power-driven hammer.
Hammer forging - The mechanical forming of metal by means of a hammer. The action of the hammer is that of an instantaneous application of pressure in the form of a sudden blow.
Hand forging - (See also Open die forging) (1) A forging made by hand on an anvil or under a power hammer without dies containing an exact finishing impression of the part. Such forgings approximate each other in size and shape but do no have the commercial exactness of production die forgings. Used where the quantity of forgings required does not warrant expenditure for special dies, or where the size or shape of the piece is such as to require means other than die forging. (2) A forging worked between flat or simply shape dies by repeated strokes and manipulation of the piece. Also known as smith forging or flat die forging.
Heat - A term used to identify the material produced form a single melting operation. Different heats of the same material can vary in chemical composition within prescribed limits. Stock from a single heat will have a consistent analysis and more uniform properties. Also known in the U.K. as "Cast".
Heat treatment - A sequence of controlled heating and cooling operations applied to a solid metal to impart desired properties.
Hot forging - Same as hot working--plastically deforming an alloy at a temperature above its recrystallization point, i.e, high enough to avoid strain hardening.
Hot working - The plastic deformation of metal at such a temperature and strain rate that recrystallization takes place simultaneously with the deformation, thus avoiding any strain hardening. Also referred to as hot forging and hot forming. Contrast with cold working.
Impression die forging - A forging that is formed to the required shape and size by machined impressions in specially prepared dies that exert three-dimensional control on the workpiece.
Inclusions - Particles of nonmetallic compounds of metals and impurity elements that are present in ingots and are carried over in wrought products. The shape and distribution of inclusions are changed by plastic deformation and contribute to directionality in metals.
Induction heating - Heating metals by means of alternating magnetic field.
Ingot - A casting intended for subsequent rolling, forging, or extrusion.
Isothermal forging - A hot-forging process in which a constant and uniform temperature is maintained in the workplace during forging by heating the dies to the same temperature as the workpiece. Most commonly conducted at about 2000ºF under a controlled atmosphere or in a vacuum to prevent oxidation while forging superalloys.
Lubricant - A material applied to dies, molds, plungers, or workpieces that promotes the flow of metal, reduces friction and wear, and aids in the release of the finished part.
Match -A condition in which a point in one die half is aligned properly with the corresponding point in the opposite die half within specified tolerance.
Microstructure - The structure and internal condition of metals as revealed on a ground and polished (and sometimes etched) surface when observed at high magnification (over 10 diameters).
Multiple - (1) Term used to describe a die impression designed to produce more than a single piece at a time. (2) A piece of stock for forging that is cut from bar to billet lengths to provide the exact amount of material needed for a single workpiece.
Near-net-shape forging - Forging components as close as possible to the required dimensions of the finished part.
Net-shape forging - Forging components on one or more sides to net shape requiring no further machining on at least one side (e.g., net forged gear with machined back face).
Open die forging - Forging produced by working between flat or simply contoured dies with unrestricted metal flow using repetitive strokes and continuous manipulation of the workpiece; sometimes called hand forging.
Open dies - Dies with flat surfaces that are used for preforming stock or producing hand forgings.
Pickling - The process of removing oxide scale from forgings by treating in a heated acid bath.
Power-driven hammer - A forging hammer with a steam or air cylinder for raising the ram and augmenting its downward blow.
Precision forging - (See also Net-shape forging) A forging produced to closer tolerances than normally considered standard by the industry.
Press - A machine tool with a stationary bed and a slide or ram that has reciprocating motion at right angles to the bed surface; the ram is guided in the frame of the machine.
Punchout - Metal removed when punching a hole in a forging.
Ram - The main reciprocating member of a press, guided in the press frame, to which the punch or upper die is fastened.
Slug - (1) Forging stock for one workpiece cut to length. See also Blank. (2) Metal removed when punching a hole in a forging (also termed "punchout").
Smith forging - See Flat die forging, Hand forging.
Steam hammer - A type of drop hammer where the ram is raised for each stroke by a double-action steam cylinder and the energy delivered to the workpiece is supplied by the velocity and weight of the ram and attached upper die driven downward by steam pressure. Energy delivered during each stroke may be varied.
Stock - The material to be forged regardless of form. Also an individual piece of metal used to produce a single forging.
Strain rate - The rate at which metal is deformed.
Structural integrity - Inherent microstructural soundness of forgings as a result of achieving 100% density, uniform metallurgical structure and grain size, as well as the absence of porosity, segregation, large inclusions, and other non-forged part defects.
Thermomechanical processing - A general term covering a variety of processes combining controlled thermal and deformation treatments to obtain synergistic effects, such as improvement in strength without loss of toughness.
Tolerance -The permissible deviation from a specification for any design characteristic.
Tumbling - (1) The process for removing scale from forgings in a rotating container by means of impact with each other and abrasive particles and small bits of metal. (2) A process for removing scale and roughness from forgings by impact with each other, together with abrasive material in a rotating container.
Upsetter (Forging machine) - A horizontal forging machine where the workpiece is gripped between two grooved dies and deformed by a punch that exerts force on the end of the stock.
Warm forging - Deformation at elevated temperatures below the recrystallization temperature. The flow stress and rate of strain hardening are reduced with increasing temperature; thus, lower forces are required than in cold working. For steel, the temperatures range from about 1000ºF to just below the normal hot working range of 1900 to 2300ºF. See also Cold working and Hot working.
1. These targets have been revised on the basis of discussion at the workshop, and a revised set of strategic targets is included as Exhibit 6-2.
2. As a separate exercise, the Quality and Productivity work group identified four projects that could be immediately recommended as projects for MPLUS: 1) development of user-friendly simulation software; 2) development of real-time hot dimensional measuring capabilities; 3) development of vibratory signature analysis equipment for the forging industry; and 4) development of technology to internally inspect the ingot.