Metal forging plays an important role in the manufacturing industry.
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In this eBook, we will explain you all aspects of metal forging.
It is designed for both experts and non-experts in the forging industry.
We aim to provide you the basic and advanced foundation of metal forging.
Forging refers to a manufacturing process where materials are subjected to compressive forces/stress.
According to the Collins dictionary, it is the process of producing various parts by hammering.
The force changes the shape of the metal to form the desired shape.
The magnitude of the force will depend on the type of metal and type of machines among other factors.
Basically, forging is an example of deformation process.
The process is classified based on an environment the manufacturing process takes place.
Thus, it can be classified broadly as hot or cold forging. This refers to the metal forming temperature. (You will understand it in next chapter)
This manufacturing technique has been around for years.
In fact, the tools that were used before Homo sapiens existed were produced by metal forging.
It is one of the oldest metal working arts.
At times, one may refer to it as primitive blacksmith &#; Iron Age.
In fact, these were very rudimentary tools ever created by the ancient man.
The early man depended on a rudimentary manufacturing process.
That is, they could deform material parts using bare hands.
Apparently, this no longer the case.
Why ?
This has been replaced by machines. It was during the industrial revolution that man adopted the use of machines.
Modern forging machines are effective and efficient.
They can forge both small and large equipment. That is, from small bolts to turbine rotors.
Despite being an ancient technology, it has been adopted even in the modern metal part manufacturing.
This is due to the wide range of benefits it has to offer.
Machines that are used in modern part processing are efficient, reliable and more sophisticated.
This guarantees a high level of accuracy and precision.
In fact, with these machines, it is possible to obtain very complex shapes.(like below one for brass parts)
By deforming the work piece, one can create a desired geometrical shape.
This is due to the plastic deformation.
Normally, it is used to process all metals such as steel, iron, brass, etc.
In most industries, the individual metals must be tested to determine the technique that should be adopted.
Therefore, the technician or the engineer should understand the basic principles that govern the entire process.
It is important that you understand every aspect of the entire process to be able to make informed decisions.
Forging process refers to all the steps that engineers and technicians use to shape the metal into a desired shape.
In the modern manufacturing process, it is to produce complex shapes with minimal secondary operations.
At times, they may not be manufactured using a single metal forging technique.
This may involve a number of metal fabrication techniques.
There are a number of factors you need to consider in any metal forging works.
Any technique adopted for a manufacturing process should relate to the exact specifications of the final product.
It is worth considering how a given technique will affect the final grain structure of the metal.
Check 3 most important ones:
To get components with improved physical properties, it is important that the technique aims at refining grain structure of the metals.
Normally, during plastic deformation,metals tend to change their structural composition.
That is, the orientation of grain pattern may change.
During forging process, metal can be subjected to a number of processes.
This aims to transform the material to a desired shape.
1.Forging Parts CAD Drawing
Before any metal fabrication , to get an accurate component ,you will always need a CAD drawing to confirm all details like shape, size etc.Sometime you even need the 3 D print to see how your components will look like.
You also need a deep drawing to confirm the follow thing:
At times, deep drawing may not be a single process. It may involve a series of process such as: blanking, drawing, piercing and trimming.
This forging technique is mainly used to increase the cross sectional area of metal at the expense of length.
Up-setting force can be applied in the direction that is parallel to the length axis.
It is commonly used in manufacturing processes such as production of bolts.
In this metal forging technique, the cross-sectional area of metal decreases as the length of the metal is increased.
A reasonable amount of force is applied to the work piece when the bottom of the fuller is maintained at an angle hole.
At the same time, the stock heated as the fuller top is kept above the stock.
This technique is commonly used to make the internal combustion of engines.
It is one of the most common type of drop forging operation.
In this process, the metal is manipulated into the desired shape by striking it between two dies.
Generally, the metal flow is always confined in the horizontal direction.
This is one of the most common forging operations.
It is mainly needed for those parts that should be used near bends.
Metal/material to be punched is placed on a hollow cylindrical die.
It is commonly used to produce holes in the work piece.
This is used to refer to the process of joining two metals.
It aims at increasing the length of metal.
You can achieve this through hammering or pressing.
The process is carried on a forging shop, hence the name forged welding.
This process is mainly used to separate materials into pieces.
In most cases, a hammer or chisel. It&#;s done when the metal is in red hot condition.
This forging technique is mostly used as secondary operations.
It is mainly used to eliminate the corrugated surface of the final product.
It is mainly used to obtain a smooth surface.
This manufacturing process is suitable in operations where the length of the final product should be reduced to a desired shape.
It involves the use of rapid hammer blows.
In most cases, the final product has a reduced cross section that can be used in threading, tapping or threading.
In summary, there is some of the most common metal forging process.
The choice of a particular process depends on the design and the quality of the final product.
Related Resources:
Types of Forging Processes
Video : Die forging process(open and closed die)
Video :Forging, Ring Rolling, Open-Die Forging, Hammer Forging
Hot Forging Vs. Cold Forging
There are quite a number of metal forging tools available.
The choice of a given tool will depend on the forging technique.
Furthermore, the type of forging machine and equipment forms an integral part when it comes to classifying different types of forging operations.
In normal industrial setup, there are four basic types of machines.
Forging hammers are classified as either broad or power hammer.
Working principle of these hammers is based on a potential energy that is converted to a kinetic energy and then to a deformation energy.
Broad hammer machine depends on the force of gravity.
This is one of the reasons why they are also referred to as the gravity drop hammers or drop hammers.
They are commonly used for the impression die forging manufacturing process.
These machines depend on the potential energy that is due to the force of gravity.
This implies that, the magnitude of force will depend on the weight of the hammer and the height.
In most cases, the height is typically less than 6 feet.
This is one of the main reasons why it is referred to as the energy restricted machine.
Depending on the design of forging hammer, they can strike between 60 and 150 blows/minute.
However, this depends on both the capacity and the size of the hammer.
Again, the die used in this forging process are expensive.
Besides, metal can be subjected to thermal shock. This can affect the quality of final part.
Forging hammers have higher forging force.
Unlike Broad hammers, the total force is due to steam/air pressure plus gravitational force.
The pressure is an induced force during downward stroke which results in a higher acceleration.
Again, the stem/air pressure can also be used to raise ram during the upstroke.
Other parameters will still remain the same as in the case of broad hammers.
The efficiency and reliability of a forging hammer.
It is important to note that the energy of hammer generates is not used to deform the work piece 100%.
That is, a greater percentage deforms work piece while others are lost in the form of noise, foundation shock, noise and heat.
This makes it important to define the fraction of energy generated by hammer that is utilized efficiently.
Normally, the efficiency is defined by the magnitude of deformation that takes place during any stroke.
This can be defined in the range: 0.3&#; Ƞ &#; 0.9. Where, Ƞ denotes the efficiency of the forging hammer.
The efficiency of the forging hammer is based on the analysis of the amount of energy generated and the amount utilized.
That is:
The energy available in the hammer (E hammer) = (w + PA) H.
Where, w is the weight of the hammer, A is the area of the piston, P is the steam or air pressure while H is the drop height.
The energy necessary (high temperature) to forge the work piece (E strain) = σf ε V. Where σ is the true stress and ε is the true strain.
There are very many types of forging presses in the industry.
The most common types of presses are the mechanical and hydraulic presses.
These machines are mainly used in situations where:
1. Better properties of the final product are a necessity.
That is, where the final product should be homogeneous.
2. A deeper penetration is required.
However, it is important to note that the initial cost of the forging equipment is slightly expensive.
These machines use hydraulic pressure to move the piston.
This explains the reason why they are referred to as the load restricted machines.
They are mainly used in the extrusion-type forging operation.
This is because, the machine can attain a full press load at all points during the stroke.
These machines are also associated with longer contact time, especially at the die and metal interface.
This due to the slow speed.
In such situations, there&#;s a possibility of die deterioration and heat loss.
Hydraulic presses are more accurate.This is the main reason why they are used in applications that require very tight tolerances.
Again, it is worth noting that, they are more expensive than hammers and mechanical presses.
These machines have crank presses with the ability to translate rotary motion to a reciprocating linear motion.
Depending on specified requirements, this will result in a total energy that can forge a work piece.
That is,
Where W is the total energy required, I is the moment of inertia of the flying wheel, ω is the angular velocity, ωo is the original value while the ωf is after the deformation of the work piece.
Mechanical presses are distinguished by the fact that, their ram stroke is relatively shorter than either the hydraulic press or hammer.
In most cases, these presses are always rated based on the magnitude of force they can develop at the end of each stroke.
In general, these are the two main types of forging presses.
Again, the efficiency and quality of the final product will depend on selecting the right die.
More importantly, it will depend on press sizing.
Most presses that are available in the market can attain as high as 60,000 tons.
In most cases, establishing the right force should be based on the following key criteria:
This should be based on complexity of the part.
Normally, it should be within this range 6&#; K &#; 10.
Therefore, the force required to forge a part can be determined by K*Y*A.
In addition to these, the forging machines have different values of velocity.
That is:
It is upon the technician to choose one that meets the requirement of a given application.
This should be based on speed, force it can attain, accuracy and efficiency.
Related Sources:
Drop Forging Hammers
Forging Machinery
Metal forging companies can choose from a wide range of materials.
The choice of a particular material is based on specific application of every part.
This implies, one has to be very specific on chemical and physical properties of the individual metals.
Brass is one of the most popular alloys that can be forged.
This is mainly due to the fact that it can be shaped to the desired shape easily.
Brass is known for its good formability and high thermal properties.
It is a copper alloy that offers a wide range of benefits and has been incorporated in a number of applications.
These are some of the main reasons why brass is commonly used in a number of industrial applications.
The forging brass, identified as C is rated 100%. It is the most forgeable. Others contain 35% to 40% of zinc are rated at 90%.
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There are quite a number of alloy steel forging that are used in different manufacturing industries.
Some of the most popular alloys include the , and . There are other types of steels with nearly the same chemical and physical properties. However, there are some variations based on the elements contained.
Steel forging companies can choose from three main types of steels:
1. Carbon steels
Carbon steels have similar properties of iron. Adding more carbon makes it difficult to weld or deform and cracks easily.Which will make it difficult to forge.
2. Alloy steels
Alloy steels have greater strength, hardness, wear resistance and enhanced toughness. Often you may need additional heat treatment to achieve all these.
3. Stainless steels
Stainless steels contain higher amount of chromium. They are corrosion resistant and do not rust.
It is upon the metal fabrication technician to opt for a metal that suits a specific application.
That is, one they can be transformed without exerting extreme forces.
To forge steel, the technicians can adopt cold, warm and hot.
By adopting right technique, metal forging company can produce stronger and durable steel parts than cast or machined parts.
With right forging technique , steel parts will possess the following key properties:
Forged steel parts are used in a wide range of applications that may include manufacturing cranes, cables, hydraulic press, shafts and axles for drives.
These parts are used in production, automotive and chemical manufacturing industries.
Most common aluminum alloys include , , and .
Aluminum has become popular across very many industries due to its light weight.Check one list from slideshare .
Aluminum forging is popular due to the superior physical and chemical properties.
elementalmatter.info has a great article for the Aluminum properties,check it here :
Some of the main reasons why aluminum forging is highly recommended in most industries include:
So why aluminum is highly recommended in most industries ?
Dig it with the following 5 points:
1. High strength to weight ratio.
This makes it a perfect choice for a number of applications such as automotive, wheels, airframes and panels.
2. Superior corrosion resistance
Aluminum forged parts do corrode, even when they&#;re subjected to most adverse weather conditions.
This is the main reason why they are used in the petrochemical and marine industries. In fact, most fasteners in these industries are manufactured from aluminum.
3. Wear resistance and durability
This makes it a perfect choice for most automotive industry applications.
4. It is a versatile metal that be manufactured with a wide range of metal forging processes.
5. Its soft compared to other materials such as iron. This reduces the production cost.
Like other metals, iron forging is also popular across very many industries.
Iron parts are used to manufacture and upgrade components.
With the required equipment, they can be crafted/manipulated to meet the exact requirements of the end user.
In most industries, iron is considered a super alloy. This is due to the fact that, the forged parts are mainly used in high temperature applications.
Iron forged parts are less expensive as compared to other alloys such as the nickel or cobalt-based alloys.
In addition to these, the iron based alloys can be hot or cold worked. This will depend on the final physical and chemical properties that one wishes to achieve.
Iron forging is a manufacturing technique used to produce parts that should meet the following key criteria:
It is important to note that the wear resistance increases with the quantity of carbon.
For instance, 611, 612 and 613 are mainly used to forge high-temperature aircraft bearings.
That is, those machine components that are subjected to any form of sliding contact.
Choosing a particular type of iron alloy for any forging process should be based on the desired applications.
Copper and its alloys used in a number of industrial applications.
This is due to its excellent electrical and heat conductivity properties.
It is known for its non-magnetic, corrosion resistance, machinability, ductility, malleability and wear resistance.
Forged copper parts are a perfect choice in applications where there&#;s higher temperatures and at a higher load.
Again, the parts can withstand high stress without unexpected failures.
In most cases, Forged copper parts are highly recommended.
Why ?
Stainless steel, which is available in 304, 314, 316 and 403,can be open die forged into different shapes.
There are about 200 grades of stainless steel to choose from.
This leaves die casting companies with a wide range of options to choose from.
In normal industrial setup, parts that can be obtained include: copper discs, shafts, rings, plates, etc.
Check Why Stainless steel is mainly used in a number of applications :
1. The forged stainless steel parts can withstand sanitizing and frequent cleaning; this is one of the main reasons why it is used in the food processing and medical equipment.
2. Highly resistant to corrosion; this is the main reason why it is used in petrochemical, marine and chemical industries, especially in pumps. These parts can withstand prolonged exposure to corrosive environment.
3. The forged parts have high resistance to heat. This makes it a perfect choice for furnace, heat sinks and ovens.
4. They guarantee high wear and high performance. This explains the reason why they are used for landing gears and motor components.
5. The forged parts have high stability and strength. This makes it a perfect choice for most structural components.
In short, stainless steel is one of the most popular materials used to manufacture a number of industrial parts. This is because having some of the best physical and chemical properties.
Related Resources:
Forging Materials: Plain-Carbon and Low-Alloy Steels
Forging Tooling and Materials
Applying a compressive force at specific temperatures has both advantages and disadvantages.
It is one of those manufacturing process that depend on temperature.
Ideally, the main advantages and disadvantages of the process can be discussed based on the type of the forging process.
That is,
whether it is hot forging or cold forging. May be, we need to clarify these terms first before we look at the advantages and disadvantages of each process.
The two processes are slightly different, however, they produce the same results.
Metal is heated to a temperature above the recrystallization temperature.
A desirable compressive force is applied to manipulate metal to a desired shape.
During this period, the metal is subjected to a number of strain hardening effects.
The temperature will depend on the metal to be forged.
For example:
Cold forging
The metal is subjected to compressive forces at temperatures below the recrystallization temperature.
This is actually the opposite of hot forging.
Normally, it&#;s the room temperature. The most common process that is used is the impression-die casting. It is a perfect choice for soft metals.
1. The parts have increased ductility and strength; this makes them a perfect choice for most applications.
2. Flexibility; hot forging is more flexible than cold forging. This is because customized parts can be manufactured easily.
3. Superior surface finish; this allows for a number of finishing operations such as painting, coating or polishing.
4. High temperature removes any homogeneous substances. This is due to the increased diffusion.
5. There is a reduction in the pore size.
Like other manufacturing processes, this process has certain disadvantages.
This forging technique is used in most industries.
Check the advantages below :
This manufacturing process may not be adopted in certain applications due to 4 reasons :
Therefore, it is important that one evaluates both the advantages and disadvantages of the two processes.
This is an effective way to adopt a reliable, efficient and cost effective metal forging technique.
Related Resources :
Advantages and disadvantages of closed die forging
Both casting and forging are essential manufacturing processes in metal fabrication industry.
Choice of a particular process will mainly depend on the specific manufacturing objectives one would wish to achieve.
In most cases, people tend to confuse casting and forging manufacturing processes.
In this section, we shall define each manufacturing process.
We shall also highlight some of the main reasons why you need to adopt a specific casting or forging for a given application.
In metal casting, metal is heated to a molten state, poured into a mold to create a desired shape.
Distinct facts about casting
Forging
Forging is the process of manipulating the shape of a metal by subjecting it to compressive forces.
Unlike the metal casting process, in this process, we don&#;t need to melt the metal. A die is used to transform the metal into a desired shape and size.
Distinct facts about forging
Above are clear differences between forging and casting. Manufacturers should choose a technique based on quality of final products.
Relate Source :
Difference Between Casting & Forging
Forging vs. Casting: Which is better?
Steel Fabrications vs. Castings
Forged Versus Cast Irons &#; Is One Better Than The Other?
Companies have invested in precision forging alongside other open-die forging techniques.
It&#;s due to increasing demand for forged products.
Items include components used in both light and heavy machines that are used in different industries.
Examples of applications are:
This is one of those industries that has benefited from this industry.
Products include complex shapes that have been manufactured either through cold or hot forging.
Examples of parts include: automatic and manual transmission systems, steering parts, engine parts, etc.
Like the automotive industry, there are a number of forged parts that are used in this industry.
Examples include: inner-outer ring, taper roller bearing outer ring, bearing and other engine and transmission parts.
Others include engine discs, compressor parts, exhaust, spinners and other aircraft structural parts.
Forged parts include turbine components, discs, shafts, seamless pipes and fittings, just to mention a few.
Generally, nearly 43% of the parts that are used in this industry are manufactured through forging.
Forged precision parts include: bars, welding products, gaskets, washers, etc. This is mainly due to their structural integrity.
A number of medical equipment are forged. These include trauma parts, extremities parts, implants and medical machine parts.
Generally, precision forging has become part of our daily life.
All that matters is the ability to get quality products that can meet the specific requirements of the end users.
The technology is still improving and soon, we&#;ll have even better engine parts and equipment.
Like other professions, a number of stakeholders and companies have formed associations that oversee how people go about their business in the forging industry.
Again, their mandate is to set rules that everyone in the industry should follow.
Moreover, they provide educational materials and avenues of connecting all metal forging companies globally.
Association Of Indian Forging Industry
This association aims at promote the interest of the forging industry in India.
Apparently, there are over 173 ordinary members and about 45 Associate Members of the Association. The members include corporations, companies, person or firms.
The Association of Indian Forging Industry (AIFI) aims to promote interest of forging industry.
It puts more emphasis on manufacturing and other fabrication processes.
AIFI enhances skills and promotes professionalism. This is through educational videos and publications.
AIFI also participate in both national and international seminars. Soon, members will also be able to advertise with AIFI.
Forging Industry Association
The Forging Industry Association (FIA) aims to connect producers, suppliers, designers, buyers and students.
FIA provides a wide range of information aiming to increase global competitiveness in the forging industry.
It provides opportunities within the industry: career information, forge shop information and learning material. There&#;s membership services too.
China Forging Industry Association
It has about 450 forging operations. This accounts for about 90% of total forging production in China.
China Forging Industry Association (CFIA), is part of the Confederation of Chinese Metalforming Industry (CCMI).
The membership consist of learning institutions and metal forming enterprises/companies.
Like of other metal forging associations, CFIA strives to ensure quality manufacturing process.
CFIA organizes conferences, exhibitions, publishes magazines, oversees research and avails learning resources.
The association champions for cost effective and sustainable forging processes.
Generally, there are many forging associations in the world today.
It is important that one becomes a member of this a forging association, especially those who are in the forging industry.
Metal forging is an integral part of any manufacturing process in the modern industrial setup.
It is important that one chooses an effective a reliable technique based on the specific requirements of the end user.
When you know all aspects of metal forging , you will benefit a lot if your product parts made from the metal forging process.
Now it&#;s turn,leave a comment and tell me what you think about metal forging.
Cold forging machines are essential in the metalworking industry, providing efficient and precise solutions for shaping metal parts at room temperature. These machines enhance product strength, surface finish, and dimensional accuracy, making them indispensable for manufacturing automotive components, fasteners, and various industrial parts. Understanding the types, features, and considerations for purchasing cold forging machines can significantly enhance production capabilities and product quality. Exapro, a leading online marketplace for used industrial machinery, offers a diverse selection of cold forging machines, providing businesses with access to high-quality equipment at competitive prices.
Cold forging machines come in various types and configurations to meet specific production needs and applications. The primary types include:
Mechanical cold forging presses utilize a mechanical flywheel to store energy, which is then rapidly released to forge metal parts. These machines are known for their high-speed operation and are suitable for high-volume production.
Hydraulic cold forging presses use hydraulic cylinders to apply force, offering greater control over the forging process. These machines are suitable for precision forging operations and can handle larger and more complex parts.
Servo presses use servo motors to control the forging process, offering precise control over force, speed, and position. These machines are ideal for complex and high-precision forging operations.
Specialized cold forging machines are designed for specific applications, such as the production of fasteners, gears, and other specialized parts.
Exapro offers a variety of cold forging machines, ensuring businesses can find equipment that meets their specific production needs.
When selecting a cold forging machine, it is crucial to consider specific features and specifications to ensure the machine meets your operational requirements. Key factors include:
The forging force and capacity of the machine determine the types and sizes of parts that can be forged. Machines with higher tonnage are suitable for forging larger and more complex parts. Exapro&#;s listings provide detailed specifications on forging force and capacity, helping you find a machine that matches your production needs.
The speed and cycle time of the machine impact overall production efficiency. High-speed machines are essential for large-scale operations, while lower-speed machines may suffice for smaller production runs. Consider the machine's strokes per minute (SPM) and cycle time to ensure it meets your production volume requirements.
Advanced automation and control systems enhance precision and consistency in the forging process. Features such as programmable settings, touch-screen interfaces, and real-time monitoring capabilities can significantly boost productivity and ensure consistent product quality. Exapro&#;s platform includes machines with various levels of automation, allowing you to find the right balance between functionality and ease of use.
Ensure the machine is compatible with the materials you need to forge, such as steel, aluminum, copper, and other metals. Machines that can handle a range of materials offer greater flexibility and versatility in your operations.
The durability of the machine and its maintenance requirements are essential for long-term operational efficiency. Machines constructed from high-quality materials, such as hardened steel, are more resistant to wear and tear. Easy-to-clean designs and accessible components simplify maintenance, reducing downtime and operational costs. Exapro provides information on the condition and maintenance history of used machines, aiding in informed decision-making.
Reputable brands and manufacturers are often synonymous with higher quality and better support. Some leading brands in the cold forging machine market include:
Exapro features equipment from these and other reputable brands, ensuring access to reliable and well-supported machinery.
The cost of used cold forging machines varies widely based on factors such as age, condition, brand, and specific features. Generally, prices can range from several thousand to several hundred thousand dollars. For example, a used National Machinery single-action press might be priced around $20,000 to $50,000, while a high-end Hatebur servo press could cost between $100,000 and $300,000. Exapro's marketplace offers a range of pricing options, providing transparency and competitive deals for buyers.
Cold forging machines are essential tools in the metalworking industry, offering efficient and reliable solutions for shaping metal parts with high precision and strength. By understanding the different types of machines and key factors to consider when purchasing, businesses can make informed decisions that align with their production needs. Exapro offers a comprehensive platform for sourcing high-quality used machinery, providing detailed listings and competitive pricing. Whether you need a mechanical press, hydraulic press, servo press, or a specialized forging machine, Exapro&#;s extensive inventory and user-friendly interface make it easy to find the right equipment for your cold forging operations.