5 Key Forging Applications Where Automation is Driving Change 

Integrating advanced technology into forging plants not only offsets cumbersome manual labor but are also significantly boosting productivity, improving efficiency, and achieving superior quality control. The key player in these advancements? The 6-axis robot.

The Role of the 6-Axis Robot in Forging Automation

Many forging plants operate with older equipment that wasn’t originally designed for automation integration. The 6-axis robot stands out as the central piece of equipment enabling seamless integration with other advanced technologies. Specifically, the FANUC Foundry Pro series design is tailored for the extreme conditions of forging plants, because of its ability to withstand high temperatures, handle heavy payloads, and adapt to diverse applications.

1. Loading Raw Product into the Furnace

This process used to be a manual, labor-intensive task prone to injuries. However, advancements such as 3D robotic bin-picking allows robots to intelligently locate and pick parts from bins, increasing flexibility and efficiency.

These systems are equipped with advanced vision system, including cameras and 3D sensors to help the robot understand and perceive the location/orientation of parts in the bin. Coupled with magnetic gripping technology, the robot can dynamically pick steel billets in almost any configuration, handling varied weight and sizes. 

2. Transferring Hot Product from Furnace to Forge and Through Forge Dies

This application presents unique challenges due to the extreme heat and abrasive conditions. Automation addresses these challenges with specialized technology designed to complement the 6-axis robot’s capabilities. These technologies include:

· Heavy-Duty Conveyors: High-temperature chain conveyors for transporting glowing hot materials.

· Heat-Resistant Grippers: Pneumatic grippers with heat shielding and water-cooling features for prolonged durability.

· Temperature Sensors: Designed to monitor glowing red-hot parts for precise handling.

3. Automated Die Spraying 

Spraying dies with lubricant is another step in the forging process where automation can be very effective. Although the technology is not highly advanced, fine-tuning the systems for optimal performance ensures longevity and efficiency.

Top components include:

· Accurate dosing pumps to ensure proper lubrication mixture.

· High-volume diaphragm pumps to facilitate fluid movement.

· Atomizing valves and flow meters for precision spray patterns.

· Pinch valves to prevent clogging when using high-solid-content lubricants.

4. Moving Forged Products for Trimming 

Efficiently transferring parts between presses demands high-speed conveyors, vision-guided systems, and specialized grippers.

Loading the trim press with a robot is quite straightforward, however the removal of flash after the trimming process can be a very challenging task due to the unpredictable nature of the process. Creative designs involving various equipment & technology such as actuators, air cannons, machine vision and often die modifications, can be leveraged to tackle this challenge.

5. Inspection of Finished Products

By leveraging automated inspection, plants gain tighter control over their production processes, improving both accuracy and reliability. Advancements in sensor technologies and software platforms are pushing the boundaries of quality control. Modern automated inspection ensures consistent product quality while significantly reducing inspection times.

Innovations include:

· 3D scanning for automated defect detection and detailed metrology.

· Advanced cameras and sensors paired with AI algorithms for real-time analysis.

· Software platforms that make this cutting-edge technology easy to use in production environments.

Automation is the Future of Forging

Automation is no longer optional—it is a necessity for forging plants looking to maintain efficiency, ensure worker safety, and deliver high-quality products in today’s competitive market. By adopting advanced systems like the FANUC Foundry Pro series and integrating custom-made solutions for key stages of the forging process, you can revolutionize your plant’s productivity and quality.

Don’t know where to start? Contact an Adaptec expert to discuss how you can implement automation tailored to your specific needs. Together, we’ll forge a path to a more efficient future.