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Forging Is A

Forging is a manufacturing process that shapes metal using localized compressive forces from tools like hammers and dies. It can be classified by the temperature used - cold, warm, or hot forging. Forged parts range in size from under a kilogram to hundreds of metric tons. Forging has been done for millennia and is now a major worldwide industry. The main forging equipment includes anvils, tongs, chisels, swage blocks, and swages. The main forging processes are open-die drop forging, closed-die drop forging, and impression-die forging.

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33 views

Forging Is A

Forging is a manufacturing process that shapes metal using localized compressive forces from tools like hammers and dies. It can be classified by the temperature used - cold, warm, or hot forging. Forged parts range in size from under a kilogram to hundreds of metric tons. Forging has been done for millennia and is now a major worldwide industry. The main forging equipment includes anvils, tongs, chisels, swage blocks, and swages. The main forging processes are open-die drop forging, closed-die drop forging, and impression-die forging.

Uploaded by

Sahil
Copyright
© © All Rights Reserved
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Download as PDF, TXT or read online on Scribd
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Forging:-

Forging is a manufacturing process involving the shaping of metal using


localized compressive forces. The blows are delivered with a hammer (often
a power hammer) or a die. Forging is often classified according to the
temperature at which it is performed: cold forging (a type of cold working),
warm forging, or hot forging (a type of hot working). For the latter two, the
metal is heated, usually in a forge. Forged parts can range in weight from less
than a kilogram to hundreds of metric tons. Forging has been done by smiths for
millennia; the traditional products were kitchenware, hardware, hand
tools, edged weapons, cymbals, and jewellery. Since the Industrial Revolution,
forged parts are widely used in mechanisms and machines wherever a
component requires high strength; such forgings usually require further
processing (such as machining) to achieve a finished part. Today, forging is a
major worldwide industry.
The forging process is very important and has an indispensable position among
various manufacturing processes generally adopted in workshops since it
provides a number of advantages, as given below:
1. It refines the structure of the metal
2. It renders the metal stronger by setting the direction of the grains
3. It effects considerable saving in time, labour and material as compared to
the production of similar items by cutting from a solid stocks and then
shaping it
4. Since the production of articles with reasonable degree of dimensional
accuracy is possible the machining operation can be divided in most of
the cases.
Components of Forging:-
The hand forging equipment’s are.
Anvil:
Anvil is used to support work pieces during hammering.

 The body is made of mild steel.


 It has a strip of high carbon steel welded on it is top to provide hard face.
 The anvil body consists of a round hole and square hole.
 Round hole is used for bending cylindrical rods.
 Square hole is used for holding square shanks of various tools.
 Horn (or) beak provided are used for bending the metal into round shapes.

Tongs:

 Tongs are used to hold the job during forging operation.


 These are made up of mild steel.
 They are usually made in two parts and are hinged by means of rivets.
 The smaller length from the hinge carries the holding jaws and the longer length
forms the arm.
 It is held by the worker to apply pressure for holding the job.
Chisels:

 Chisels are the tools used for cutting metal and necking prior to breaking.
 Chisels are two type they are Hot Chisel and Cold chisel.

Hot Chisel:

 Hot chisel are used for cutting metal when it is in hot state.
 The edge of the hot chisel is made with 30 degrees and is not hardened and
tempered.
 The chisels are having different shapes according to holding metals

Cold chisel:

 It is used for cutting metal in cold condition.


 The cold chisel edge made with 60 degrees and it is hardened and tempered.

Swage block:

 Swage block is generally used for bending, forming, heading, knocking up


heads, squaring operations.
 Swage block is made of cast iron and high quality blocks are made of ductile
iron (or) low carbon cast steel.
 It consists of grooves on the edges and holes in the body of swage block.

Swages:

 Swages are consist of two parts the top part provided with handle and the other
is the bottom part provided with square shank which fits into the square hole
provided in the anvil.
 Swages are used to reduce and finish round square and hexagonal shaped work
piece.

Process:-
Drop forging:-
Drop forging is a forging process where a hammer is raised and then
"dropped" onto the work piece to deform it according to the shape of the die.
There are two types of drop forging: open-die drop forging and closed-die drop
forging.
Open-die drop forging
Open-die drop forging (with two dies) of an ingot to be further
processed into a wheel
Open-die forging is also known as smith forging.[8] In open-die
forging, a hammer strikes and deforms the work piece, which is placed on a
stationary anvil. Open-die forging gets its name from the fact that the dies (the
surfaces that are in contact with the work piece) do not enclose the work piece,
allowing it to flow except where contacted by the dies. The operator therefore
needs to orient and position the work piece to get the desired shape. The dies are
usually flat in shape, but some have a specially shaped surface for specialized
operations. For example, a die may have a round, concave, or convex surface or
be a tool to form holes or be a cut-off tool.[9] Open-die forgings can be worked
into shapes which include discs, hubs, blocks, shafts (including step shafts or
with flanges), sleeves, cylinders, flats, hexes, rounds, plate, and some custom
shapes.
Advantages of open-die forging

 Reduced chance of voids


 Better fatigue resistance
 Improved microstructure
 Continuous grain flow
 Finer grain size

Impression-die forging:-

Impression-die forging is also called "closed-die forging". In


impression-die forging, the metal is placed in a die resembling a mould, which
is attached to an anvil. Usually, the hammer die is shaped as well. The hammer
is then dropped on the work piece, causing the metal to flow and fill the die
cavities.
Depending on the size and complexity of the part, the hammer may be
dropped multiple times in quick succession. Excess metal is squeezed out of the
die cavities, forming what is referred to as "flash". The flash cools more rapidly
than the rest of the material; this cool metal is stronger than the metal in the die,
so it helps prevent more flash from forming. This also forces the metal to
completely fill the die cavity. After forging, the flash is removed.
Advantages-

 The internal grain structure formation increases the tightness and strength of the
products
 Economic for large production
 No material limitations
 Better surface finish
 Less or no manufacturing required

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