May 2022 Volume 4

EQUIPMENT & TECHNOLOGY

Cost Savings and Significant Minimization of Recalls Quality issues with a forged product can have a wide variety of reasons. Typical forging defects such as underfills, overlaps, or notches are very difficult to capture and measure. Thanks to the high level of quality assurance in forging shops, such defects are extremely rare. However, when they do occur, the economic cost can be considerable. Martin Scholles: "With iForge Traceability, forging companies can now trace the defect to see if it's a one-off error or a systemic fault. In most cases, the defect can then be narrowed down to just a few products, so significantly less financial cost is incurred. Automotive manufacturers also benefit from this, as potentially only the vehicles in which the identified as installed need to be specifically recalled. The same goes for components that are used in the aviation industry. Here, the part history can be read and traced directly on the aircraft using the laser code." Where Quality Assurance and Process Optimization Start Built-in sensors continuously gather process data, store them in an endless database, and assign them from the beginning to a single part number, which is applied to the work piece immediately after forging. SMS-METRICS is used as an effective tool for acquiring, storing, and evaluating machine data, in real time, along with the data from the iForge Traceability module. The evaluations can be easily created in the browser, dynamically adapted, and retrieved from any location worldwide. High Cost Efficiency In addition to the indirect advantages described, iForge Traceability also directly contributes to improving cost efficiency. For example, defective components can be identified and removed quickly and early, before further added value goes into the part. Processes can be stabilized, and the overall equipment effectiveness (OEE) enhanced by making automatic corrections during manufacturing. In this way, buffer stocks can be reduced or eliminated. In conjunction with optical systems that perform the final inspection process, the whole process can be largely automated. The Process:The Best of BothWorlds inOne Solution In developing iForge Traceability, the R&D experts at SMS group have combined two processes in one solution: Dot peen marking for code marking in the high-stress process part and laser marking (with additional information such as customer and supplier details) for the finished part with final contour. This ensures that every single work piece has its own fully traceable data record.

AMust-Have: For Retrofits and New Equipment In terms of both the equipment and control technology, the new systemcan be integrated into existing facilities. iForge Traceability is an excellent example of the digitalization solutions from SMS group that offer customers an array of possibilities. All new plants from SMS group are now equipped with a basic digitalization package that is ready for today and future and extension capability. With iForge modules, customers can decide what individual services and solutions they would like to implement to meet their requirements." Setting The Course Today for The Digital World of Tomorrow Dr. Thomas Winterfeldt, Head of Forging Plants at SMS group: "Working in conjunction with our subsidiary SMS digital, we have the know-how, the experts, and the research and development capacities to digitalize a host of other processes in the field of forging technology and to generate real and effective added value for plant owners. At the same time, our Technical Service team at SMS group is a lifecycle partner who not only ensures your forging equipment remains available on an ongoing basis but also implements new solutions in existing plants and offers innovative and cost-cutting service concepts. In this way, we meet our objective of being the leading partner in the world of metals in every respect."

Martin Scholles, Senior Sales Manager Closed-die Forging Presses, SMS group GmbH, martingerhard. scholles@sms-group.com

Axel Rossbach, Technology Manager Forging Plants, SMS group GmbH, axel.rossbach@sms-group.com

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