November 2024 Volume 6

OFFICIAL PUBLICATION OF THE FORGING INDUSTRY ASSOCIATION | FORGING.ORG | NOV 2024

THE FORGING FOUNDATION & RESEARCH

PAGE 52

Funding the Future of the Forging Industry Page 55

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PRESIDENT'S NOTE

PRESIDENT'S NOTE

W ith the U.S. election behind us, here is to four years of expected restraint of new regulations for manufacturers; reinstatement of R&D expensing legislation critical for capital expenditure planning and continued favorable taxation rates of our members’ businesses. Many economists have suggested plan ning for a sluggish Q1 and Q2 for

Most of these funds will filter down to members and industry in the form of forging improvement contracts. Some of the funds will benefit the FIERF Forging Competitions, the ICON (a casting, forging and machining RFQ database) development which the mili tary uses, and finally some funds to assist with FIA administrative costs to manage these projects and member contracts. To that end, we are fortunate to have a very capable Technical Director on the FIA Team (Dekland Barnum) with the skill set and technical back ground to help us grow the DOD effort at FIA. Dekland has fit right in with the organization and made immediate positive impacts in his first year. The Year Ahead 2025 brings us another FIA offering - Forge Fair and the excitement and expectation of 150+ exhibitors and 2,000 attendees. In 2024 we have been at some attendance record setting shows (AISTech, Automate) and heard of other's shows setting attendance records. We expect the same for Forge Fair 2025, which again returns to Cleveland. Our Forging Lightweight Alloys event returns to the schedule in Long Beach, CA with some exciting presentations and tours planned. With the great success of our combined FIA Fall Meeting & Marketing Seminar in 2024, we expect to continue this approach. As we look at FIA standing committees, our newest efforts – Women in Forging and Next Gen – are very popular and growing and offer several opportunities to meet throughout the year. The Public Policy Committee continues to grow with members, and we continue our quest to initiate a closed-die trade case with the USTR/USITC to address foreign forgers who dump forgings or are subsidized by their governments. There is continued harm to a sizable portion of our membership, and we will never give up on addressing this to protect our members and demand a level playing field. On behalf of FIA and FIERF’s boards and our staff, we wish you a wonderful holiday season with your family and look forward to a successful year in 2025.

the year’s start. With such an election mandate delivered by voters, perhaps we can be optimistic that businesses and consumers will react positively with their spending, and we will get back to improved forging levels sooner than the mid-year mark. A Quick Look Back We are in the home stretch for closing out the year with Thanks giving and December holidays right around the corner -- such a valuable time to celebrate and reconnect with family, and also an important time to relax and recharge ourselves for the next year. It was a momentous year for FIA and I’m so proud of our FIA and FIERF Boards for their leadership and our incredibly capable staff for delivering some impressive wins. Membership: Continues to grow with several more forging producers added in 2024. Looking back at the last 30 years, we are at a high water mark with overall members at 230. When asked ‘what attracted you to FIA,’ new members often mention our training (live and Forging University), our Government Affairs visibility, and our overall visibility as an association which amplifies our number one mentioned benefit – networking. Forging Foundation: New initiatives including Forging Clubs, Forge the Future Summer Camps, the FIERF Forging Competi tion, and the Forging with Freddy childrens’ book series continue to grow as we focus on developing the workforce at a younger age. DOD and Government Affairs: Starting with a modest DOD five year award in 2020 of $485k to support our Forging University upgrade, the FIA Board and our members who support our lobbying efforts, our lobby firms and staff to date have secured an additional $5.6 million (FY24) with an additional $5 million for FY25 with approval expected 12/31/24. (Note: look for an FIA project call in the Spring 2025).

James R. Warren President and CEO Forging Industry Association

PUBLISHER James R. Warren jwarren@forging.org MANAGING EDITOR Angela Gibian angela@forging.org Editorial Staff

Board of Directors

Antonio Alvarez Robert Brodhead Robert Dimitrieff

Chelsea Lantto Louis Philippe Lapierre Jose Lozano Mike Morgus Matt Natale

ASSOCIATE EDITOR Amanda Dureiko amanda@forging.org DESIGN Lorean Crowder lorean@forging.org

CHAIRPERSON Jim Kravec VICE CHAIRPERSON Joe Schwegman

Bret Halley Jeff Krueger

FIA MAGAZINE | NOVEMBER 2024 1

CONTENTS

NOVEMBER 2024 | VOLUME 6

46 100% First Year Talent Retention in Manufacturing is Possible 48 Welcome New Members 50 Remembering William “Bill” E. Hoban 51 FIA Upcoming Events FOUNDATION NEWS 52 Third Annual FIERF Forging Competition to be Held at Forge Fair 2025 53 FIERF Funded Forging Clubs 54 FIERF Hosts Two Forge the Future Summer Camps 55 Funding the Future of the Forging Industry 58 FIA Technical Update 60 FIERF Donor Spotlight: Alton Steel FORGING RESEARCH 61 FIERF is Now Accepting Research Grant Applications 62 FIERF Research Grants & Project Updates 66 Predicting the occurrence of central burst during open die forging of high strength steels: A metallurgical and mechanical analysis MEMBERS SPEAK 70 Forging Day: Inspiring the Next Generation of Forging Industry Leaders AD INDEX 73 November Advertiser Index

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PRESIDENT'S NOTE 1 President's Note WASHINGTON UPDATE

MAINTENANCE 18 Project Management for Forging Equipment Rebuild AUTOMATION 20 Transforming Billet Handling with Flexible 3D Robot Vision MATERIALS 23 2024: Challenging Year for SBQ Suppliers OPERATIONS & MANAGEMENT 26 NLRB’s General Counsel Declares “Stay-or-Pay” Provisions Unlawful, Employers Given 60 Days to Comply 29 What is Your AI Strategy? 32 Forging Company Maintaining your Insurance Coverage in Today’s High Liability Environment 34 Innovating Workplace Culture in the Forging Industry 37 This Poll Will Still Be Relevant After Election Day 40 How Zero-Trust Cybersecurity Can Benefit Your Business INDUSTRY NEWS 42 Recap of the 33rd Forging Industry Technical Conference 44 Member Spotlight: FICEP

4 Trump II: Tariffs on “Day One”? 6 FIA Launches Media Campaign to Highlight Industry’s Forging Capacity for Government & Defense Components ENERGY 8 Skyrocketing Capacity Costs and Their Impact on Your Energy Spend EQUIPMENT & TECHNOLOGY 10 The Next Level of Axial Forming for a Sustainable Component and Process Chain Design 15 A Single-Source Solution for Ring Manufacturing 16 Pioneering Precision in a Rapidly Evolving Industry

OFFICIAL PUBLICATION OF THE FORGING INDUSTRY ASSOCIATION | FORGING.ORG | NOV 2024

THE FORGING FOUNDATION & RESEARCH

PAGE 52

Funding the Future of the Forging Industry Page 55

For advertising contact info@forging.org

FIA Magazine (ISSN 2643-1254 (print) and ISSN 2643-1262 (online)) is published 4 times annually, May, August, November and February by the Forging Industry Association, 6363 Oak Tree Blvd., Independence, Ohio 44131. Telephone: (216) 781-6260. Only (1) copy of the print version distributed at no charge only to members of the Forging Industry Association. Digital version distributed at no charge to qualified individuals. Subscription requests available at www. forging.org. Printed in the U.S.A. Periodicals postage paid in Independence, OH and additional mailing offices. POSTMASTER: Send address changes to Forging Industry Association, 6363 Oak Tree Blvd., Independence, Ohio 44131. Copyright © 2024 by the Forging Industry Association in both printed and electronic formats. All rights reserved. The contents of this publication may not be reproduced in whole or part without the consent of the publisher. The publisher is not responsible for product claims and representations or for any statement made or opinion expressed herein. Data and information presented by the authors of specific articles are for informational purposes only and are not intended for use without independent, substantiating investigation on the part of potential users.

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FIA MAGAZINE | NOVEMBER 2024

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TRUMP II: TARIFFS ON “DAY ONE”? By Omar S. Nashashibi WASHINGTON UPDATE

T he following numbers are not area codes: 122, 201, 232, 301, 338, 421. These are different sections of trade laws that President-elect Donald Trump could use to impose tariffs and import restrictions after he takes office on January 20, 2025. U.S. manufacturers, their customers, and overseas competitors should prepare for a second Trump administration that is expected to move much more swiftly than the first. Candidate Trump famously called the tariff the “most beautiful word” in the dictionary, and we may hear him use it often once he occupies the Oval Office. In his first term, roughly eleven months passed between the time President Trump announced tariffs on China and when they actually took effect. This delay was largely a function of a first-term president who had not made plans to govern, should he win the 2016 election. This time around, the institutional knowledge is in place, an understanding of the process is clear, and the sense that he will move on "Day One" is resonating throughout Washington. Unlike tax policy, President elect Trump can move virtually unimpeded on tariffs, without the burden of congressional oversight and with little opposition in the courts, which often cite the power Congress ceded to the president over trade policy since the 1930s. Unlike the first Trump administration, sources indicate that the president-elect increasingly views tariffs less as leverage in negotiations and more as a policy tool in and of themselves. Tariffs, as a central element of an industrial policy, would embed this trade tool into virtually every aspect of manufacturing, from inputs to final assembly.

Using tariffs as a strategic tool—not as a mechanism to alter supply chains but to boost domestic industry—would mark a significant shift from the original intent of tariffs. It is clear that under a second Trump administration, all supply lines will now go through Washington, D.C. Returning to the “area codes” of tax law, discussions in Washington over the China tariffs currently focus on whether President-elect Trump must conduct a new Section 301 investigation to expand or increase tariffs on Chinese imports. Many believe that since the U.S. government has already concluded a Section 301 investigation into imports from China, it can simply proceed with raising tariff rates, and possibly expanding the scope of goods covered. Forgoing a new investigation would allow for quicker action without having to seek public input, a process that can take months. The Forging Industry Association (FIA) has long contended that a 25 percent tariff on imported Chinese forgings is woefully insufficient. FIA members regularly report a price discrepancy of 40-70 percent between the U.S. and China, as most, if not all, forgings from China are subsidized by the Chinese Communist Party-run government. The FIA will work with the incoming Trump administration, as we have with the current White House, to address the shipment of underpriced and subsidized forgings into the U.S., as well as around the world, originating from or subsidized by the Chinese government. Under U.S. trade and administrative procedural rules, the federal government often must undergo a notice-and-comment period to solicit public input prior to imposing new tariffs. This is a step

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FIA MAGAZINE | NOVEMBER 2024

WASHINGTON UPDATE

the Trump administration will likely seek to avoid in order to expedite the imposition of tariffs on imports. A Section 301 pathway is possible, as are a few options under existing trade law that would allow the administration to bypass a lengthy government investigation. When a president calls for tariffs on imports, it can prompt several agencies and departments to initiate formal proceedings. These investigations can take anywhere from three to eighteen months, or even longer, which is why the Trump administration will likely use a combination of trade tools to move more quickly. President-elect Trump could initiate a Section 122 balance-of payments tariff under his authority in the Trade Act of 1974, resulting in an immediate additional 15 percent rate for 150 days unless extended by Congress. Under the same law, he may also have the ability to block the importation of certain products for a period of time, again without a public review process. Section 421 of the Trade Act of 1974 allows the president to impose temporary tariffs on Chinese imports in the event of a surge in shipments into the U.S. that cause market disruption for domestic manufacturers. Regardless of which trade provision is used to impose tariffs, President-elect Trump will face no shortage of options. China, however, has taken steps since the first Trump administration to lessen the impact of tariffs on its economy. Retaliatory tariffs from China, as well as from any allies subject to tariffs, are expected. China and the EU strategically targeted politically sensitive industries, often in Republican-leaning congressional districts and states, during Trump’s first term. The tariffs placed on U.S. exports to China covered goods ranging from steel and aluminum to vehicles, whiskey, and soybeans. In 2016, China sourced 40 percent of its soybean imports from the U.S.; today, that figure stands at just 18 percent, as Brazil has emerged as the largest supplier to China. Should Beijing impose tariffs on U.S. goods, exposure for Chinese industry is less significant today than it was in 2018 when the Section 301 tariffs first took effect. China is also taking extraordinary steps to evade tariffs by investing in manufacturing facilities in Mexico, allowing those products to enter the U.S. as "Made in Mexico" and thus avoid tariffs or duties. Forgers in the U.S., Mexico, and Canada are now competing with the Chinese government right across the southern border, an issue FIA will continue to press with the Office of the U.S. Trade Representative under President Trump.

FIA is well positioned to work with a second Trump administration and the new 119th Congress, which will convene in January 2025. In lobbying meetings on Capitol Hill and with the Biden administration, we have witnessed a significant shift in the perception of tariffs. Once viewed as a "protectionist" measure to defend domestic industry, under a second Trump administration, tariffs may become the bedrock of an offensive trade policy, providing U.S. manufacturers with a longer runway to compete against manufacturers subsidized by Beijing. Regardless of the trade tool used, President Trump will be ready to act on Day One.

Omar S. Nashashibi is the Founder of Inside Beltway, a nonpartisan lobbying and strategic consulting firm in Washington, D.C. Having worked in the nation’s capital for over twenty five years, Mr. Nashashibi provides strategic consulting services to companies while also lobbying the White House and Congress on behalf of manufacturing, associations, defense firms, nonprofits, and other sectors. He works with policymakers on trade, taxes, environmental and workplace regulations, supply chains, job training and identifying grants and funding to support projects. Having

started his career in Washington D.C. in 1996, Mr. Nashashibi worked for the Office of Management and Budget, a branch of the White House, a large multi state law firm, and founded a previous lobbying firm in 2005. He graduated from the George Washington University in Washington, D.C., where he studied Political Science and International Affairs.Washington, D.C. representing the Forging Industry Association. He can be reached at omar@insidebeltway.com.

Perks Marketplace FIA Member only benefit

Visit www.Forging.org and click on Member Discounts to access your savings. For more information on all of your FIA Member Benefits, contact Tricia Abruzzino at tricia@forging.org or call 216-781-6260.

FIA MAGAZINE | NOVEMBER 2024 5

FIA LAUNCHES MEDIA CAMPAIGN TO HIGHLIGHT INDUSTRY’S FORGING CAPACITY FOR GOVERNMENT & DEFENSE COMPONENTS By Laura Johnson WASHINGTON UPDATE

O ver the past several years the belief that our members lack capacity within the defense and commercial arenas has become a commonplace theme when speaking with a Prime or the DOD. Even when responding in the affirmative on the topic, forgers inevitably receive the follow up, “are you sure?” Without a doubt, this has become a maddening trend, but a trend that FIA has prioritized their efforts to change perceptions and minds. But how did we arrive at this point? Like many products that came before, cheaper costs pushed production out of the United States, which drained our capabilities and capacity to turn an order around quickly. In search of the lowest price possible, the Primes and DOD inadvertently were partly to blame. In an effort to begin turning these opinions around, the FIA recently launched a PR campaign focused on forgers’ capacity. Over the next several months, our target audience will begin to see and feel the campaign through a combination of online advertising, social media and traditional press including op-eds and interviews. The campaign’s home can be found on FIA’s website, where the audience can view the campaign’s overview video, links to mentions in the press, facts and figures and the data that supports our assertion – U.S. forgers have the capacity to meet the moment.

at 85% (factoring in normal downtime and assuming sufficient operating capability). Over the period from 1972 to 2022, average capacity utilization in manufacturing was 78.2%, with utilization rates exceeding 90% only during wartime.

Given this, we can see that forgers in fact have the capacity to do additional defense and commercial work if it is available. With the campaign, it is our intention to push back against this misunderstanding and demonstrate that the forging industry has the capacity to produce all that is needed!

To lend credibility to the campaign, the FIA brought on Wipfli, a top 20 advisory and accounting firm, to conduct the member surveys that provide the hard data used throughout the campaign. Wipfli regularly conducts market research within the manufacturing industry to examine key trends, benchmarks, and forecast indicators. The Wipfli team carefully analyzed the data from the survey to complete this study. As of September, the average capacity of our forgers is at 51.2%. Our expected 2024 overall capacity utilization is 50%. Companies that are primarily doing defense industry work have the lowest capacity utilization at 41%. Full capacity utilization in manufacturing is accepted

Laura Johnson Government Affairs Director Forging Industry Association Email: Laura@forging.org Phone: 216-781-6260

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FIA MAGAZINE | NOVEMBER 2024

ENERGY

SKYROCKETING CAPACITY COSTS AND THEIR IMPACT ON YOUR ENERGY SPEND By Nancy Gardner

O ne of the largest line items on your energy bill is for some thing called “capacity costs,” an amount you pay to ensure your energy provider can fulfill your energy needs at all times (especially times of heaviest use; i.e., that they always have the capacity to keep your lights on and forging equipment firing). Some thing big recently happened that is going to negatively impact your capacity charges if you operate plants in PJM, the Regional Trans mission Organization that manages the electric grid across 13 states (DE, IL, IN, KY, MD, MI, NJ, NC, OH, PA, TN, VA, WV) and the District of Columbia. While many FIA members do have manufacturing facilities in PJM, the dynamics impacting capacity costs described in this article are also at play across the U.S., so please take note. Wherever you do business, capacity and other ancillary charges are generally on the rise, making the task of managing energy budgets increasingly complex. That said, here’s what you need to know. On July 20th, 2024, PJM announced the results of its annual Base Residual Auction (BRA) for the 2025-2026 delivery year (06/01/25 05/31/26). This auction sets the capacity prices that power providers must pay to ensure reliable electricity supply. As a result, PJM reported a 750% WEIGHTED AVERAGE INCREASE in capacity costs compared to the prior year. This will have a significant impact on your organization's energy bills.

• This dramatic rise in capacity prices is driven by several factors, including fewer power plants bidding into the auction, fore casted growth in electricity demand, and regulatory changes. How Can You Mitigate the Impact? While the capacity price increase is unavoidable, there are steps you can take to manage the other half of the capacity cost equation - your electricity demand: • Implement Demand Response programs to reduce usage during peak hours. • Deploy energy management software to optimize your facilities' energy consumption. • Explore load shifting, energy efficiency, and energy storage solu tions to lower your Peak Load Contribution (PLC) values.

Frequently Asked Questions What is the Expected Cost Impact?

Nearly every third-party supply agreement covering electricity rates within the PJM service territory includes language to adjust for changes in capacity costs relative to the results of the annual Base Residual Auction. Utility supply tariffs are similarly structured to pass through any cost increases or decreases relating to capacity auction prices. In 2024, capacity accounted for an average of 7-8%

of total electric supply costs. Considering the RTO-average increase from $28.92 to $269.92 (+833%), that figure is set to increase substan tially. Cost adjustments will depend on a variety of factors (utility, rate class, load factor, etc.) but initial projections point to an estimated increase between $0.010 - $0.016 per kWh. Why Did Capacity Costs Increase? PJM sited three primary drivers of higher capacity prices: 1. Fewer offers into the auction - due to power plant retirements, the number of assets entering bids into the auction was less than in prior years.

What Does This Mean for You? • Capacity costs, which typically account for 7-8% of your total electricity spend, are set to rise substantially. • Your third-party supply agreements and utility tariffs include provisions to pass through changes in capacity costs, so you will see these increases reflected in your energy bills regardless of your energy buying strategy.

2. Forecast growth - increasing reliance on electricity in the trans portation, data center, and heating sectors is expected to drive demand growth. 3. FERC implemented several market reforms including measures to adjust for extreme weather and verify each resource's ability to perform as intended.

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FIA MAGAZINE | NOVEMBER 2024

ENERGY

the five highest-demand intervals during the prior summer (referred to as 5 Coincident Peak, or 5 CP hours). PJM assigns a PLC value to each meter based on its individual contribution to total load when the grid is under the most stress. These 5 Coincident Peak hours typically take place on summer weekday evenings between 4pm and 8pm. In 2023, the 5 CP hours occurred on July 27, Sept 5, July 28, Sept 6, and July 5. All of these occurrences took place between 5pm-6pm when grid demand exceeded 137,800 MW. PLC values for 2024 were determined by each meter's electric demand during these summer 2023 hours. What Else Should You Know About PJM's Base Residual Capacity Auction? - A total of 133,684 MW of capacity cleared in the Base Residual Auction. Incremental auctions will be held in the future to secure additional capacity for 2025/2026. - Resources clearing in the auction included natural gas (48%), nuclear (21%), coal (18%), Demand Response (5%), hydro (4%), wind and solar (1% each). - The 2026/2027 Base Residual Auction is scheduled to take place in December 2024.

Can Anything be Done to Avoid These Cost Increases? The auction established the value of each MW of capacity. That makes up one half of the equation that establishes final capacity costs, and this change was unavoidable. The other half of the equa tion is manageable, as it depends on electric demand during the 5 CP hours. Lower PLC values will result in reduced electric supply costs. Opportunities to control PLC values include Demand Response, energy management software, load shifting, energy efficiency, and energy storage. What is a Capacity Auction? In a capacity auction, the grid operator dictates how much capacity will be required to meet demand in future years. Power generators then determine how much electricity they will be able to provide at a given price. Once the amount of electricity offered meets the target demand figure, the price of the final MW entered into the auction sets the clearing price. PJM hosts annual capacity auctions in order to secure generation resources to meet expected demand in future years. Capacity payments are made to electric generators, efficiency resources, and Demand Response assets that have demonstrated the ability and willingness to generate (or curtail) electricity during periods of peak grid demand. Capacity payments are an additional

revenue stream for power generators on top of energy payments received for every kWh of electricity generated (or avoided) in the wholesale marketplace. The purpose of these auctions is to provide price signals to investors who can then determine whether or not it makes sense to invest capital to build a new power plant. Typi cally, these auctions occur three years prior to the delivery period to allow ample time planning and participation. Due to numerous delays by PJM and FERC, this latest auction took place less than a year

Transparent Energy is here to help. As your trusted energy partner, we can analyze your portfolio, identify cost-saving opportunities, and develop customized strategies to minimize the impact of these capacity cost increases. And with a new capacity auction on the horizon in PJM (December 2024), the threat of even higher capacity charges ahead for 2026 and 2027 requires proactive planning and action. Contact us today to learn more. Nancy Gardner Transparent Energy Email: ngardner@transparentedge.com Phone: 732-288-5126

before the changes will take place, allowing little time for consumers to budget or take action to reduce peak load contribution (PLC) values. How are Capacity Costs Calculated? All types of electric generators (natural gas, nuclear, coal, wind, solar, etc.) bid in certain amount of capacity (in MW) that they are willing to provide at a certain price point. Prices are stated in dollars per megawatt day ($/MW-d). This means that for each MW that clears the auction, the generator will receive the auction clearing price every day for the entire planning year. Along the same lines, end-users will pay the auction price of capacity for each MW of demand, as defined by the peak load contribution (PLC). EXAMPLE: A customer with a PLC of 1 MW (1,000 kW) will pay $269.92 every day in capacity costs. ($269.92 * 365 days * 1 MW = $98,520.80). What is PLC? Peak Load Contribution (PLC) is a defined figure for every electric meter within PJM. The number is determined by calculating the average electric demand (in MW) for each meter as recorded during

FIA MAGAZINE | NOVEMBER 2024 9

EQUIPMENT & TECHNOLOGY

THE NEXT LEVEL OF AXIAL FORMING FOR A SUSTAINABLE COMPONENT AND PROCESS CHAIN DESIGN Chipless Manufacturing of Helical Gears Dr.-Ing. N. Missal, Felss Systems GmbH, Königsbach-Stein S. Schwertel, Felss Systems GmbH, Königsbach-Stein M. Ludwig, Felss Systems GmbH, Königsbach-Stein

B ased on the state of the art, the known manufacturing processes for producing external helical gears generally possess specific disadvantages, e.g., high material waste, extremely high tool wear, energy inefficiency, required assembly processes, or insufficient gearing quality. As a result of further development of the Felss core technology – the axial forming process – the mentioned negative effects can be partially or completely avoided. The axial forming process and the new associated machine concept developed as part of a feasibility study allow the manufacture of helical gears with a significant improvement of achievable gear quality to IT5-6 with a total helix deviation of up to 10 µm. Furthermore, the application of an energy and material-efficient cold-forming process, compared to forging or machining processes, offers a significant improvement of the PCF (Product Carbon Footprint) and can provide momentous advantages concerning the sustainability of the automotive industry in series production. Introduction There are over 1.3 billion motor vehicles worldwide today, of which one billion alone are passenger cars. By 2035, this number is expected to rise to around two billion. This enormous increase in the mobility sector poses major challenges not only for Germany, but for almost all industrialized and emerging countries. Traffic- and production related emissions of CO2, air pollutants, and noise are causing prob lems, and dependence on oil imports is growing. Thus, effective climate and environmental protection targets can only be achieved if road traffic and the automotive industry also make a significant contribution. However, because many people still depend on the car, it is not enough to avoid solely on traffic and to focus on short distances and bicycles. Road traffic as well as the production of power-driven vehicles themselves, must become more environmen tally friendly with less negative impact on climate and health, and for a better quality of life in the city of tomorrow. Cold metal forming plays a major role worldwide in the production of vehicle compo nents regarding lightweight construction, sustainability, accuracy, and productivity. By utilizing material and applying a lightweight structural design, cold metal forming can significantly contribute to

reducing the CO2 footprint and emissions of the entire process chain at acceptable costs through innovative solutions [1, 2]. The Felss Group is a globally well-known solution provider in the field of cold forming for the automotive industry. With 100 years of experience in niche technologies, Felss has been able to target rotary swaging and axial forming for the reduction of component weights. As an established lightweight design expert, Felss focuses on identi fying and implementing individual, optimal, sustainable customer oriented solutions and applying them for product development, from the machines to the finished component. Considering the increasing importance of environmental aspects, Felss concentrated its devel opment resources in recent years strongly on generating customer benefits, such as reducing the CO2 footprint. These efforts resulted in entirely new forming processes and the further development of the existing core technologies, rotary swaging, and axial forming. The achieved extension of axial forming process limits, which now enables the production of helical gears, has already been published in [9]. Therefore, the focus of this publication represents the devel opment of the new axial forming machine. State of the Art Axial forming belongs to incremental forming processes, and the principle is shown in Figure 1a. A gear forming tool, e.g., a die, forms the teeth in the axial direction. The gearing is thus highly precise because all teeth are generated simultaneously by a one piece tool directly on the component. Felss axial forming is gener ally carried out by the process of frequency modulation or recursive movement of the forming tool. Thereby, the forming process consists of a continuous repeat of a forward stroke and a subsequent, signifi cantly shorter backward stroke. During the backward stroke, there is no contact between the forming die and the forming zone; thus, the forming zone can be relubricated. Therefore, the typical lubri cation film breakage for the cold metal forming process caused by the high contact stresses and significant surface enlargement can be completely avoided. The frictional forces can thereby be reduced by up to 30% compared to conventional axial forming.

FIA MAGAZINE | NOVEMBER 2024 10

EQUIPMENT & TECHNOLOGY

Production of Helical Gears by Axial Forming A feasibility study was initiated based on the presented state of the art and the consider ation of the significant advantages of axial forming over other helical gear manufac turing processes. The primary objective was to confirm the applicability of axial forming for manufacturing external helical gears. In cooperation with various partners, including Hofer powertrain GmbH, two components with different gear parameters were identi fied (Table 1). This experimental trial was

Figure 1: a) Principle of axial forming, b) force curve of the axial forming process with frequency modulation

Figure 1b shows the typical force curve of an incremental axial forming process. During the forward stroke, a forming process with a positive force or pressure component of the forming force occurs. Within the backward stroke, when the die is removed from the forming zone, only the frictional forces between the die and the component exist, which cause the negative components of the force curve. As part of a feasibility study, alternative forming manufacturing processes for the production of external helical gears were first considered so that the technological disadvantages of these processes against axial forming could finally be identified. The results of this literature review showed that axial forming combines the advan tages of the impact extrusion and rolling processes compared to the conventional metal forming manufacturing processes. Through the application of axial forming with frequency modulation as an incremental process, high contact stresses and high tool wear can be avoided. The main competitor to axial forming is the hobbing process. Axial forming can be considered as a new forming alterna tive to gear hobbing, which completely avoids material waste due to the full utilization of material and, thus, reduces material costs and the CO2 footprint. Moreover, forming in a one-piece tool results in an excellent total cumulative pitch deviation so that gear qualities of IT5-6 can be achieved compared to IT7 by hobbing. Furthermore, the axial forming process enables a compact design of the toothing because a distance of only 1.5-2 mm after the gear to the next shaft shoulder is necessitated. The long run-outs after the gear teeth, which are a technological requirement in gear hobbing, are therefore no longer necessary within axial forming [3 through 8]. Summarized, the analysis of state of the art showed that the described forming and machining processes are generally only suitable for external gearing. The production of internal helical gears is mainly realized by further machining processes, such as broaching, skiving, or flow-forming. However, these processes can only be applied to through holes and don’t offer any application possibility for gears in blind holes. The axial forming also, in this case, offers an economical alternative to machining and additionally provides the possibility for the manufacturing of internal helical gears in blind holes. A detailed analysis of the state of the art can be found in [9].

carried out according to [9] on an existing Felss Aximus H02 axial forming machine which was retrofitted with a driven tool carrier with a worm gear unit and servomotor. Thereby, a standard frequency modulation and a standard oil for highly loaded forming processes were applied for the forming of the helical gear components. The tolerances achieved in the trial (Figure 3a) demonstrate that forming an external gear through axial forming with a helix angle of 22° using the driven tool carrier is feasible. Moreover, similar quality ratios were determined for all gear components independent of gear heights and helix angles.

Table 1: Experimentally investigated helical geared components The gear component tolerances specified by the customer were achieved with the exception of the total helix deviation F β , and thus, axial forming was verified as a forming alternative to hobbing. The tolerance of total helix deviations F β of the helical gear compo nents produced on the Aximus H02 by axial forming showed a very specific trend over the length of the gearing which correlates with the occurrent varying load in the gearing die during forming. This observation indicates that there is a relationship between the finished part quality of the gear component and the occurrent different load dependent machine torsion. The forming of the gearing can be divided into three different load areas or forming areas on the component (cf. Figure 3a, red lines). The start of gear forming represents the first area where the required axial and torsional forces increase continuously to their maximum until the die-filling of the gear is reached. The subsequent main forming area extends over almost the entire length of the gear and

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offers very constant forming conditions due to the complete contact between the component and the forming die. In the remaining forming area at the end of the gearing, the forces drop again by reducing the contact between the component and the forming die. In order to reduce the dependence of the gear quality on the unavoid able load changes of the forming process, a study was carried out on the economic realization of the greatest possible torsional stiffness of different axial forming machines and their tool guidance design concepts. A FEM-based software Meshparts was used for this study. This offers the possibility to efficiently analyze the deformation of various machine designs via structural-mechanical simulations under the forming load and to evaluate their potential influence on the gear quality. Due to the complex and component-intensive machine design, the simulation model is reduced to the main supports of the machine frame within the forming process (Figure 2). For the simulation, unnecessary construction elements, such as smaller radii and bores, were neglected. The reduction of the simulation model and the simplification of the contours made a drastic reduction of the calcu lation effort possibly due to the lower number of required meshing elements of approx. 1.2 million without any significant influence on the investigated result. In accordance to the standard machine design, the bearing and contact surfaces were respectively defined, and the machine frame was preloaded via the tension rods. The other specified boundary conditions describe the maximum machine load during the forming process of a helical gear. This is represented by the application of a constant torsional force by the driven tool carrier corresponding to 9000 Nm and the application of the asso ciated reaction torque to the clamping device for component fixing. Moreover, the axial load of the forming process is also calculated by 400 kN, which is applied through the connecting surfaces of the hydraulic feed cylinder and the clamping device.

to a torsion angle of 0.05588 degrees, whereby approx. 98% of the total torsion occurs due to the torsion of the driven tool carrier and its guides. The first optimization stage of the horizontal axial forming machine was the installation of two additional guide elements, each with two recirculating ball-bearing carriages. The addition of the guide elements now stabilizes the forming tool on four posts of the machine frame preventing displacement due to torsion. This modi fication already resulted in an improvement of the torsional machine stiffness of approx. 41% compared to the reference condition and corresponds to a torsional angle of only 0.033 degrees. Based on the calculated results concerning increased machine stiff ness and its potential positive influence on gear quality, the 4-element guide concept was implemented on the Aximus H02 axial forming machine. After the upgrade was completed, the previous experi mental test was repeated. Compared to the gear results from (Figure 3a) of the conventional guiding concept, the low machine torsional stiffness against torsional forming loads could be verified as the main influence on the gear quality. Due to the new stiffened machine concept, the reduction of the previously insufficient total helix devia tions F β from over 20 μm to below 10 μm (Figure 3b) was achieved to be within the specified tolerance limits.

Figure 3: Helix corrected measurements of the gearing produced by a) the conventional forming machine, b) the stiffened forming machine (Helix angle of 10°) After additional validation tests, the actual torsion angle of 0.052 degrees in the reference condition of the axial forming machine at an applied torque of 9000 Nm was measured. There is a deviation of 5% between the calculated value and the actual value to deter mine the torsion angle. So, the simulation model provides a realistic representation of the determined torsional stiffness. After validation of the simulation model, the correlation between the new stiffened machine concepts and gear quality by the production of helical gears on vertical axial forming machines was evaluated. As both horizontal and vertical axial forming machines must be applied for the production of helical gears, a numerical investi gation of the machine frame's resilience under identical load and boundary conditions had to be carried out for the vertical machine design, as described above. The investigation of the already stiffened machine concept by integrating the previously optimized tool guid ance showed a torsional angle of 0.0407 degrees. This represents an improvement in torsional stiffness of only 27% compared to the

Figure 2: Simulation model of the horizontal forming machine with applied forces and torques The standard design of the die guidance system of a conventional, horizontal axial forming machine, which was installed to produce the first helical gears shown in Figure 3a, was defined as the refer ence condition for this investigation. This die guide consists of four recirculating ball-bearing carriages which guide the forming tool in the press space by two diagonally positioned guide elements. The numerically determined total torsion of this machine type amounts

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horizontal reference state. This significant drop in torsional stiffness compared to the stiffened horizontal axial forming machine results from the omission of support for the upper and lower base plates of the machine frame (Figure 4). Whereas the mounting points of both base plates via the common machine base counteracts the torsion of the horizontal press frame, further optimization steps are required for the vertical machine design. Due to the solid ram design and the installation of four or optionally eight recir culating ball-bearing carriages, a significant stiffening could be achieved. This results in a stiffness improvement of the vertical axial forming machines of approx. 70% compared to the reference state, so the torsion angle amounts to only 0.17 degrees. Machine torsion occurs from insufficient tool guidance. There fore, the new simplified vertical machine frame was developed for a complete machine concept based on the data obtained from the numerical investigation. The main focus was on implementing the greatest possible machine stiffness so that acceptable gear quality within the production of greater helical gears in the future could also be achievable. The optimized design of the machine frame and the ram unit is shown in Figure 5. According to the simulation model. Thus, the ram unit consists of a solid ram plate (yellow) axially supported by eight recirculating ball-bearing carriages along the guide rails. The bearing package for absorbing the axial forming forces during the turning of the forming tool is situated inside this ram plate. It has been designed for a minimum space requirement. In this design, the driven tool carrier has been extended by a second servo motor in order to generate greater torques with simultaneously higher positioning accuracy and, thus, to improve the achievable gear tolerances. Moreover, the forming tool can now be decoupled from the driven tool carrier by a short-stroke cylinder. Therefore, damage of the already formed gearing during the ejection by the uninhibited torsion of the forming tool can be completely prevented. Further more, a direct measuring system can be installed on the rotary bearing at a later date in order to be able to track the actual posi

Figure 4: Simulated deformation of the loaded axial forming machine with a) the stiffened design with 4 guide elements and b) with the optimized machine design

tions and actual velocity of the driven tool carrier during the axial forming process with maximum precision. Although the optimized design of the ram unit results in a significant dimension increase, the maximum ram stroke remains constant or is even longer due to the simultaneous extension of the press frame. Therefore, this new machine concept can manufacture longer helical gears in the future. This new machine concept for the manufacture of high-precision helical gears was developed on the basis of investigations by struc tural-mechanical FEM simulations and designed for high rigidity, especially with regard to torsional loads. In the future, this machine concept will be applied to manufacture a wide range of helical gears according to the achievable gearing parameters, component dimen sions, and the corresponding tolerances. In order to get the newly developed machine concept ready for series production, the simula tion results concerning numerically determined torsion angle will be evaluated by carrying out experimental trials. An overview of the achieved simulation accuracy as well as the influence of the new machine concept on the gear qualities and tolerances will be repre sented in a further publication after completion of the experimental trial. Conclusion The Felss axial forming is not only capable of manufacturing simple spur gears but is also suitable for the production of helical gears due to the modified machine design. In order to achieve gearing quali

ties of IT5-6 and to comply with marketable gearing tolerances, the conventional axial forming machine had to be extended by a driven tool carrier and stiffened to support the occurring torque. By a complex synchro nization of the turning drive and the recur sive stroke, the manufacturing of external helical gears with a helix angle of up to 22° has already been achieved with process stability. Through additional stiffening of a horizontal axial forming machine, the reduc tion of the previously high total helix devia tion up to 10 μm could be realized, which makes an economical application of axial

Figure 5: Optimized design of the vertical axial forming machine

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forming for the production of helical gears feasible. The vertical axial forming machines possess significantly lower torsional stiffness due to their design, so a completely new ram guide concept had to be developed for these forming machines. Using the numerical opti mization process (FEM-based software Meshparts), the simulated machine deformation under the maximum permissible load was reduced by 70% compared with the reference condition. In combina tion with a high-powered drive and high-precision measuring tech nology, the production of helical gears on vertical axial forming machines can be not only feasible to achieve precise gear tolerances but also a significant expansion of the gear parameters and dimen sions that can be generated. [1.] Wurm, T.; Busse, A.; Raedt, HW.: Initiative Massiver Leichtbau – Phase III: Werkstofflicher Leichtbau für Hybrid-Pkw und schweren Lkw. ATZ - Automobiltechnische Zeitschrift 121 (2019) p. 16-23 [2.] Bundesministerium für Umwelt, Naturschutz, nukleare Sicher heit und Verbraucherschutz: Warum überhaupt Elektromobilität?. 2020, https://www.bmuv.de/WS706 [3.] Kiener, C.; Merklein, M.: Research of adapted tool Design in Cold Forging of gears. International Journal of Material Forming. 2020, p. 873-883 [4.] Lange, K.; Kammerer, M.; Pöhlandt, K.; Schöck, J.: Fließpressen. Berlin, Heidelberg: Springer-Verlag 2015

[5.] Verzahnungswalzen, Broschüre, Frauenhofer-Institut für Werkzeugmaschinen und Umformtechnik IWU, Chemnitz 2021 [6.] Neugebauer, R.; Hellfritzsch, U.; Lahl, M.: Advanced process limits by rolling of helical gears. International Journal of Material Forming. 2008, p 1183-1186 [7.] Degner, W.; Lutze, H.; Smejkal, E.; Heisel, U.; Rothmund, J.: Spanende Formung. München: Carl Hanser Verlag 2015 [8.] Klocke, F.: Fertigungsverfahren 1. Berlin: Springer Vieweg 2018 [9.] Missal, N.; Schwertel, S: Innovative cold metal forming processes for a sustainable future. International Conference on Gears 2023

Contact persons:

Andrew Rush Sales and Service Manager North America Felss Systems GmbH Phone: +1 262-374-3369 Email: Andrew.Rush@felss.com

Andreas Wächter Area Sales Manager Felss Systems GmbH Phone: +4917610219978 Email: Andreas.Waechter@felss.com

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