Automation in Forging – How Robots Reduce Cycle Time

In the forging industry, time is money – every second saved in production directly impacts profitability. At Adhvika Forge Tech, we believe automation is not just the future of forging… it’s the present. Robotic automation in forging is transforming how we handle hot billets, move dies, and execute precise forging operations with speed, safety, and accuracy.

🔹 The Problem with Traditional Forging

In a conventional forging line, the billet transfer, die loading, and finished part removal are often done manually or semi-manually. This leads to:

• Longer cycle times due to manual handling delays

• Inconsistent billet positioning, affecting product quality

• Higher labor fatigue and risk of workplace accidents

• Difficulty maintaining temperature consistency during transfers

🔹 The Robotic Advantage in Forging

When we integrate industrial robots into forging lines, every step of the process is optimized:

1. Faster Billet Transfer – Robots can pick billets directly from induction or gas furnaces and place them in the press in seconds.

2. Precision Positioning – No human error; robots place billets exactly in the die cavity every time.

3. Reduced Heat Loss – Faster transfer means billets stay at optimal forging temperature, improving metallurgical properties.

4. Consistent Cycle Time – Robots don’t slow down; they maintain the same pace 24/7.

5. Multi-Operation Handling – Robots can feed billets for roughing, intermediate, and finishing operations without manual intervention.

🔹 Real-World Cycle Time Improvements

In a typical closed die automotive component line, manual billet handling takes around 8–10 seconds between operations.
With robotic handling, this reduces to 3–5 seconds, which:

• Cuts total cycle time by up to 40%

• Increases daily production output significantly

• Reduces heating energy consumption since billets remain hot

🔹 Energy & Cost Savings

Shorter cycle time = less furnace holding time and reduced power/gas usage. Over a year, this translates to substantial cost savings, especially for high-volume production.
Robotic automation also extends tool life, as consistent billet placement reduces die wear and misalignment damage.

🔹 Safety First

Forging involves extreme heat and heavy components. Robots remove the need for human operators to work in close proximity to hot metal and moving machinery, drastically reducing accident risks and improving workplace safety compliance.

🔹 Forging Consultant Gives Automation Solutions Best

We provide customized automation integration for:

• Electric Screw Presses (250–8500 ton)

• Hydraulic Press Lines

• Open Die Forging with Manipulators

• Ring Rolling Machines

• Special Purpose Forging Cells

Our turnkey automation solutions include robot selection, end-of-arm tooling design, PLC integration, safety enclosures, and complete commissioning – ensuring you get a ready-to-produce line from Day 1.

 Conclusion

Robotic automation in forging is not a luxury anymore – it’s a necessity for industries looking to improve throughput, reduce costs, and enhance product quality. With Adhvika Forge Tech’s expertise, you can achieve precision forging, faster cycles, and higher ROI without compromising safety.

📞 Call Us: +91-9801329640 | 080-22117198

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