Foundry & Forging worked example

Forging Tonnage at 92% target maximum capacity utilization: a worked example

What does the result look like when target maximum capacity utilization reaches 92%? The full calculation is worked below with real intermediate numbers. Use it when checking whether a closed-die, open-die, upset, or trim operation fits the selected press, hammer, or upsetter before scheduling or quoting.

The inputs for this scenario

  • Estimated peak forging load: 1,400 ton (unchanged)
  • Press or hammer rated capacity: 2,000 ton (unchanged)
  • Target maximum capacity utilization: 92 % (raised for this scenario; the documented default is 80)

Working through the calculation

  • Applying the documented formula (Forging Tonnage rate = estimated forging load ÷ available press or hammer rating × 100) to the inputs above produces each figure below.
  • At this operating point the engine returns 70 % for forging tonnage rate, the number this scenario is built around.
  • At this operating point the engine returns 22 points for forging tonnage gap to target.
  • At this operating point the engine returns 1,400 count for estimated forging load.
  • At this operating point the engine returns 2,000 count for available press or hammer rating.

How this compares with the baseline

  • Against the tool's baseline example, where target maximum capacity utilization sits at 80% and the headline result is 70 %, this scenario lands almost exactly on the baseline at 70 %.
  • A figure at this level is achievable when target maximum capacity utilization is genuinely sustained, not just peaked for a shift. Required load itself is an estimate from projected area and flow stress; this tool only checks the ratio, so a bad load estimate makes the utilization misleading.

Results at a glance

  • Forging Tonnage rate: 70 % (headline result)
  • Forging Tonnage gap to target: 22 points
  • Estimated forging load: 1,400 count
  • Available press or hammer rating: 2,000 count

Run it with your numbers

  • Every input above is editable in the live Forging Tonnage calculator, which recalculates instantly and can be shared with the inputs intact.

Last reviewed 2026-05-12.