Technology in Action


Twin rotating spindles cold form the metal under pressure.


designed machine from MJC, the angle is fully programmable. Tis configuration allows compression in a concentrated


area and provides a more efficient method for metal deforma- tion, while producing superior mechanical properties in the finished section. Up to 90% material savings can be achieved by the use of this revolutionary metalforming technology, in comparison to conventional machining from a solid blank. Te aim of this new CNC technology, according to MJC


company president Carl Lorentzen, is to make the aerospace engineers rethink how they design their products, so that a maximum material savings on exotic and costly metals can be realized.


Rotary Forging Comes Full Circle A brief look at rotary forging helps to show the significance


of the current achievement. A hundred years ago, an unsung American technology genius named Edwin Elmer Slick launched the first of four huge rotary forging (RF) machines at the Cambria Iron Works in Johnstown, PA. Te Slick Mills as they were known, hot-formed all manner of large circular products from railway wheels to tire molds, sleeve wheels to gear blanks until the last one was withdrawn from service by Bethlehem Steel in 1982. It seems by that time the steel casting process had improved in quality and could offer lower costs and greater flexible output than the old Slick Mill. Despite the obvious success of the Slick Mill, nothing fur-


until the 1960s, when a number of much smaller machines were developed in Europe. In the 1970s, the technology was taken up in Japan and elsewhere, becoming a topic of research and development at a number of academic institutions. Primary among these was the work carried out by Peter


Standring at Te University of Nottingham in the UK. Over a 30-year period, he developed a classification system to define all types of RF machines and used it to design and build what was, for many years, the most sophisticated RF machine in the world. Standring’s classification was based on the Euler angles


of rotation (Nutation, Precession and Spin), which are used today to determine the position of a body in space such as a satellite. Tey are also used to define the motion of the Earth as it spins through space. Nutation is the inclination of the Earth’s axis from the ver-


tical (the axis of tilt). Precession is the movement of the Earth’s axis as it rotates around the hypothetical vertical axis. In short, the Earth wobbles to produce the seasonal effects at its hemi- spheres. Spin is the rotation of the Earth about its own axis. Te possible movements of all rotary forging machines are shown in the included diagram. When coupled with a simple uniaxial die closure, the process can be used to cause signifi- cant incremental deformation using very low forces compared to other techniques of conventional metalforming. Te Nottingham work, made possible with funding from


ther of significance in RF appears to have been done anywhere Te Science and Engineering Research Council and by the 74 Aerospace & Defense Manufacturing 2014


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