In the global pursuit of automotive lightweighting and carbon neutrality, magnesium forgings have emerged as a game-changer in the automotive manufacturing industry. With a density of merely 1.74 g/cm³—35% lighter than aluminum and 77% lighter than steel—magnesium forgings can significantly reduce vehicle weight, thereby lowering fuel consumption and carbon emissions. However, the inherent softness and poor formability of magnesium alloys at room temperature pose severe challenges to manufacturing processes. It is here that servo screw presses step in, leveraging advanced technology to unlock the full performance potential of automotive magnesium forgings.

The technical advantages of servo screw presses perfectly address the processing difficulties of magnesium alloys. Unlike traditional mechanical presses with fixed stroke and speed, servo screw presses adopt a high-precision servo drive system, enabling stepless adjustment of forging force, speed, and dwell time. This flexibility is crucial for magnesium forging: during the forming process, the press can slow down at the key deformation stage to ensure uniform metal flow, avoiding cracks caused by excessive local stress; at the same time, it can apply a stable dwell pressure to eliminate internal pores, enhancing the structural integrity of the forging. Additionally, the servo system’s energy-saving feature—reducing energy consumption by 30% to 50% compared to traditional equipment—aligns with the green development concept of the automotive industry.

A practical application case in the production of automotive magnesium alloy steering knuckles vividly demonstrates this empowering effect. Previously, manufacturers relied on hydraulic presses for this process, resulting in a high defective rate of 8% due to unstable pressure control. After switching to servo screw presses, the forming process was optimized: the press adjusted the forging speed from 50 mm/s to 20 mm/s when the magnesium alloy reached the critical deformation temperature of 350°C, ensuring smooth metal filling of the complex knuckle structure. The dwell time was set to 3 seconds to compact the forging interior, and the forging force was precisely controlled within ±1% of the set value. As a result, the defective rate dropped to less than 1.2%, the tensile strength of the steering knuckle increased by 15%, and the fatigue life was extended by 20%. Moreover, the production efficiency improved by 25% due to the shortened non-forming time of the servo system.

Another notable application is in the manufacturing of magnesium alloy transmission cases. The thin-walled and uneven-thickness structure of the transmission case requires strict control over the forming process. Servo screw presses achieve multi-stage speed and force regulation, ensuring that the magnesium alloy does not deform excessively in the thin-walled area while fully filling the thickened flange part. The finished forging has a dimensional accuracy of IT7 level, eliminating the need for subsequent machining, which greatly reduces production costs. This level of precision and efficiency has made servo screw presses the preferred equipment for mainstream automotive manufacturers investing in magnesium forging projects.

Looking ahead, as global automotive regulations on emissions and fuel efficiency become increasingly stringent, the demand for magnesium forgings will continue to surge. Servo screw presses, with their unique advantages in precision control, energy conservation, and process flexibility, will play an even more critical role in promoting the large-scale application of automotive magnesium forgings. They not only solve the technical bottlenecks of magnesium alloy processing but also provide strong support for the automotive industry’s transformation towards lightweighting and greenization, driving the industry towards a more efficient and sustainable future.