Precision forging processes for high-duty automotive components

Precision forging is defined as a flashless near net-shape forging operation which generates high quality parts concerning surface quality and dimensional accuracy. In the past, precision forging processes have been industrially established for axis-symmetric parts, e.g. gearwheels and steering pinions. Further development of the technology to more complex parts, e.g. helical gears, connecting rods and crankshafts is expected to lead to a wider implementation into industry. In particular high-duty automotive components offer a wide application field for the precision forging technology. Advantages like shortened production cycles which are achieved by eliminating machining operations and the saving of raw material contribute to the ongoing cost-saving trend in the automobile industry. The design process for complex precision forged parts has to be purpose-built to consider the distinctions of this technique. This article describes the adopted methods and development process of a precision forging process exemplarily considering a helical gearwheel and a crankshaft.