Automotive parts produced by optimizing the process flow forming – machining

Due to the increasing demand for precision parts with high volumes for the automotive industry, the forming of steel has gained increasing substantial importance. Therefore, new manufacturing methods and practices for special parts have been developed with cold, warm, hot and combination forging processes. Furthermore, the demand for assemble-ready parts has largely increased, whereby a subsequent machining operation is now required to satisfy the customers expectations. This report deals with the optimization of the process flow between bulk forming of parts and the subsequent machining processes of the forgings. Several examples will demonstrate the importance of how the design of the parts have been modified in order to optimize the total manufacturing process. The key aspect of this report is to demonstrate the significance of combining the forming and machining operations to be optimized by one supplier, and how this can be more cost effective than the alternative of simply delivering a formed part which then has to be subsequently machined.