The Ohio State University is leading a transformative shift in manufacturing with its Agility Forge project, developed under the NSF-funded HAMMER (Hybrid Autonomous Manufacturing: Moving from Evolution to Revolution) Research Center. Combining robotics, blacksmithing, and advanced manufacturing processes, this innovative project is redefining how metal components are designed and produced.
What is Agility Forge?
Agility Forge is a hybrid manufacturing platform that merges traditional metal forging techniques with cutting-edge automation. Unlike conventional methods such as subtractive machining (cutting material away) or additive manufacturing (building layer by layer), Agility Forge employs metamorphic manufacturing, or robotic blacksmithing. This process deforms metals into precise shapes by applying controlled forces, allowing for rapid production of high-quality parts with minimal material waste.
At the core of the system is the Tormach 1100M CNC mill, integrated with induction heating and open-die forging technologies. The HAMMER Research Center's team adapted the Tormach platform to accommodate tool-changing capabilities, advanced pressing mechanisms, and real-time scanning systems. This setup allows for heating, forging, machining, and quality inspection—all in one compact footprint.
Tormach speaks with the HAMMER team during IMTS 2024
The Vision Behind HAMMER
Dr. Glenn Daehn, a professor of metallurgical engineering and director of the HAMMER Research Center, has been instrumental in shaping the vision for this project. Drawing on decades of expertise, Dr. Daehn has sought to bridge traditional forging methods with modern technology.
Dr. Daehn’s vision was inspired by his observations of advanced metal-forming machines in Germany and his desire to simplify the forging process using open-source tools and robotics. The result is a versatile system capable of producing complex metal components without the need for expensive dies or prolonged lead times.
Why Robotic Blacksmithing?
Robotic blacksmithing builds on the time-honored principles of metal forging, augmented by precision robotics. This approach offers several distinct advantages:
- Material Efficiency: Traditional machining wastes significant material, with buy-to-fly ratios as high as 50:1 in aerospace applications. Agility Forge dramatically reduces this waste by shaping metal instead of cutting it away.
- Enhanced Properties: Forged parts exhibit superior mechanical properties, such as strength and durability, compared to those created through casting or additive processes.
- On-Demand Flexibility: The system can produce parts directly from CAD files, streamlining production and reducing costs.
Agility Forge's induction heating system efficiently brings metal to precise forging temperatures.
Features of the Agility Forge Platform
The Agility Forge system integrates state-of-the-art tools into a cohesive manufacturing solution:
- Tormach 1100M CNC Mill: The platform’s foundation, chosen for its versatility and open-source compatibility.
- Induction Heating: Heats metal to forging temperatures efficiently and with precision.
- Open-Die Forging: Simplifies tooling requirements by using adaptable tools to shape parts.
- Real-Time Scanning: Enables immediate feedback on part geometry, allowing for in-process adjustments.
- Compact Design: Portable and efficient, the system fits into spaces typically reserved for CNC mills.
Applications Across Industries
The Agility Forge platform has broad implications for numerous sectors:
- Aerospace: The ability to produce lightweight, high-performance parts faster and with less material waste is ideal for aircraft manufacturing and maintenance.
- Biomedical Engineering: The system’s precision makes it suitable for creating custom implants and surgical tools, reducing patient time under anesthesia.
- Defense: With interest from the Department of Defense, Agility Forge is poised to play a key role in the production of large, complex parts for ground and naval systems.
Hammer Research Center's Agility Forge system.
The HAMMER Research Center is pioneering a bold vision for the future of manufacturing. By integrating traditional forging techniques with robotics and modern technology, the Agility Forge project demonstrates the potential of hybrid autonomous systems to transform industries.
With its innovative design, significant cost savings, and wide-ranging applications, Agility Forge is set to redefine what’s possible in metalworking — bridging the gap between tradition and technology for a more efficient and sustainable future.
