August 2019 Volume 1

FORGING RESEARCH

More

Integration,

Better

computational engineering (ICME), machine learning, robotics and forging. In this scenario, the robot manipulates the hot metal under a forging press. Sensor and vision systems are continuously monitoring the temperature and geometry of the forging. The sensor data feeds the machine learning system, which leverages ICME to adjust the thermal and strain profiles in real-time while incrementally controlling the final part geometry. Following initial system trials, the robotic cell will be fully integrated with CDME’s 50,000-kip Instron Servo-hydraulic machine, allowing real-time feedback and control of applied load and displacement. materials

on failed forgings, including scanning electron microscopy imaging. They also performed chemical analysis and mapping via energy dispersive X-ray analysis and crystallographic and phase mapping by electron backscatter diffraction. In the fall semester, the projects will wrap up with finite element forging simulations to link structure, properties and performance with the goal of finding root cause of the failures. Refilling theWorkforce Alleviating the disproportionate supply demand imbalance means taking initiative to re-grease the metaphorical manufacturing wheel. Industry, academia, students and (sometimes)parentsarerealizingtheurgency in balancing the equation to maintain and recharge the nation’s industrial legacy. Idle recognition is not going to help restore the void in highly-skilled employees with hot forging experience. Ohio State is stepping up its game by partnering with likeminded activists to make forging opportunities readily accessible to students enrolled in the Materials Science & Engineering, Mechanical & Aerospace and Integrated Systems Engineering departments. They are tailoring curriculum based on industry feedback and market demands in the U.S. The health and competitiveness of our economy depends on the quality and preparedness of our young people. As of autumn2018,TheOhio StateUniversity has more than 8,600 undergraduate students enrolled in the College of Engineering. These bright young minds will help balance the equation and lessen the effects of the workforce development drought. For more information, contact the Forging Industry Educational and Research Foundation (foundation@forging.org, www. fierf.org, 216-862-6967) or Steve Niezgoda (niezgoda.6@osu.edu, https://mse.osu.edu/ people/niezgoda.6).

Preparation One of Niezgoda’s goals is to better integrate the FIERF magnet program with senior design and capstone activities at Ohio State. “Sponsoring senior design projects provides FIA members with an inexpensive path for workforce development,” he says. “It’s an opportunity for industry to work with students before they graduate and potentially recruit from the best before graduation. “Often, senior design projects in MSE tend to be more R&D related, there is a desire from students to work on more applied, industry-relevant projects—something they can put on a resume that shows

Inside the new metamorphic manufacturing laboratory at OSU’s Center for Design Manufacturing Excellence

Over half of Ohio State students who major in materials science and engineering take the industry path upon graduation, versus heading straight into a graduate program. Like students of other FIERF Magnet Schools, Ohio State students enjoy inherently practical design projects that require applied engineering relevant to the forging industry. Experiences like these foster increased career readiness for students and less onboarding investment for employers.

potential employers that they can manage the types of problems that regularly arise in manufacturing.” A first trial of FIA-related senior design projects was launched in the 2018-2019 academic year. The work was sponsored by Finkl Steel, a FIERF microgrant and cost sharing from the Department of Materials Science and Engineering at Ohio State. In the fall and spring semesters, students performed advanced characterization

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