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Hot & Cold Forging Tending

HOT FORGING

Forging presses have very short cycle times, usually less than 5 seconds. Loading presses can be a tiresome operation for the operator. Robots can be deployed to pick up the hot billets from the induction furnace and load to the 1st stage (forming). As required, the same robot can be utilized to transfer to the subsequent stages of forming and trimming. 2 or 3 stage presses require multiple handling and precision loading. 2 operators are required to work in tandem. This poses a huge risk while handling red hot billets.  Die spraying tasks can also be automated.

For individual smaller presses, the component needs to be transferred from one press to another to complete the operation. The critical factor is time. All operations need to be completed within a certain time so that the component temperature is maintained before the final shape is attained. 2-3 operators are required to work in close proximity and this multiple presses and the risk posed due to the hot components is very high.

COLD FORGING

Cold forging presses have a similar requirement but with lower risk. We can offer complete turnkey solutions for unmanned operation of cold forging presses.

Installation of Robots can help by eliminate the above fatigue and risk factors associated with press loading. Foundry grade robots can be used along with heat shields to prolong the life of the robots.

 

We integrate the following elements for perfect forging press tending

  • Bulk Load Billet feeders
  • Step & Elevator feeders
  • Gravity cut bit feeders
  • Lubrication systems
  • Billet orientation sensing devices
  • Temperature sensing devices for quality assurance

BENEFITS OF ROBOTIC FORGING PRESS TENDING

  • Elimination of operator fatigue due to noise, vibration, temperature and smoke inhalation
  • Elimination of risk of injury due to hot component handling
  • Quality improvement - Rejections and inconsistency due to temperature loss will be significantly reduced
  • Productivity improvement - Typically Robot fed presses will produce 30% more than manually operated presses.
  • Flexibility - Easily reprogrammable for variant changes when compared to walk beam loaders
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SUCCESFUL PROJECTS
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YEARS OF EXPERIENCE

Industries Served

  • Automotive

    The automotive industry is a a major consumer of forged components. Engine, transmission, steering and suspension parts are typically forged because of the complex shapes required

  • Power generation and transmission

    Power industries heavily rely on forgings. Nearly 40% of parts for this industry are forged. Components such as turbine blades, shafts, discs and generator components are formed by forging

  • Agricultural & Mining

    Axle hubs, pinions, drill bits, shafts are forged due to high wear resistance. Robots form an integral part of tending to forging machines

  • Aerospace

    Landing gear parts, turbine blades, compressor parts and structural components are ideally suited for robotic tending

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FREQUENTLY ASKED QUESTIONS

Hot and cold forging tending automation uses a robot or robotic cell to load, unload, and transfer parts around a forging press. It reduces manual handling, improves consistency, and helps lower operator exposure to heat and heavy tooling.
Synapse Robotics provides robotic hot and cold forging tending solutions as part of its machine tending portfolio. The company positions these systems as turnkey automation for efficient, safe, and high-throughput forging operations.
Forging tending systems are commonly used in manufacturing environments that run repeatable press operations and need high throughput. Synapse Robotics serves industrial customers across automation-heavy sectors, including automotive and manufacturing-related applications.
Yes, but only with a properly engineered cell that accounts for heat, reach, part temperature, guarding, and end-of-arm tooling. The exact setup must be designed for the part, press, and process requirements rather than treated as a one-size-fits-all solution.
The main benefits are safer handling, more consistent cycle times, reduced dependence on manual labor, and better process repeatability. In high-cycle forging environments, automation can also help reduce operator fatigue and improve line stability.
Yes. Hot forging tending must account for heat, radiant exposure, and often more demanding environmental conditions, while cold forging tending usually focuses on fast loading, unloading, and precision part handling. The robot, gripper, and safety design are selected differently for each use case.
Suitability depends on the press type, cycle time, part geometry, part weight, required reach, and available floor space. A site-specific engineering review is usually needed to confirm robot compatibility and the best cell layout.
A forging tending cell typically uses guarding, interlocks, safety sensors, emergency stops, and controlled robot logic to protect operators and equipment. Final safety design should follow the machine risk assessment and the applicable industrial safety standards for the installation.
Yes. Robotic end-of-arm tooling, fixtures, and motion paths can be customized for different part sizes, shapes, and handling requirements. Synapse Robotics presents itself as a custom automation integrator, so application-specific design is central to the offering.
Deployment time depends on the complexity of the press line, tooling, guarding, controls, and commissioning requirements. A simple cell may be faster to implement than a fully integrated high-throughput line, so the schedule should be defined after process review and design approval.
It can reduce the need for manual loading and unloading at the press, but it does not eliminate the need for skilled supervision, maintenance, and process monitoring. The goal is usually to shift operators from repetitive handling tasks to higher-value oversight work.
Synapse Robotics states that it provides timely execution and after-sales support, which is important for industrial automation systems that require commissioning, tuning, and ongoing maintenance. For a live production cell, post-installation support is often a major factor in success.