University Of Engineering And

Technology Lahore

Group 5
Topic: Forging
Presenters: 1. Ali Haider(513)
2. Shahzaib Hassan(506)
3. Umar Saleem(514)
4. Muhammad Aqib(519)
Presented To: Dr.Aqib Mashood Khan
Contents
 Forging
 Methods And Metals
 Types Of Forging Presses
 Applications
 Advantages And Disadvantages
 Forging Processes
1. Hand forging
2. Machine forging
 Types Of Forging
1. Open die forging
2. Impression die or Closed die forging
3. Press forging
4. Hammer forging
 FORGING
Define:
It is manufacturing
process in which we forming
and shaping the metals
through the use of
hammering, pressing or rolling.
Common Examples:
.Pliers .Hammers Figure: shows Forging by
.Sledges .Wrenches hammer

.Garden tools Source: Mechanical Booster

.sockets .eye bolts
www.mechanicalbooster.co
m/2016/08/forging-vs-
casting.htm
Methods Metals
 Impression Die  Carbon Steel.
Forging.  Alloy Steel.
 Cold Forging.  Stainless Steel.
 Hot Forging.  Soft metals such as
 Seamless rolled Ring aluminum, brass and
forging. copper can also be
 Open Forging. forged.
Types of forging presses:
 Mechanical Forging Hammers Types
presses.  Lever spring hammers.
 Hydraulic Forging  Pneumatic hammers.
presses.  Steam or Air hammers.
 Screw presses  Helve hammers.
 Upsetter.
 Hydraulic hammers.
www.mechanicalbooster.com
Application:
 Aerospace,aircraft engines.
 Guided missiles and space vehicles.
 Automotive trucks, buses, trailer.
 Agriculture tools.
 Industrial and commercial machinery and equipment.
 Hand tools.
 Electric power generation/transmission.
Advantages Disadvantages
 Manufacturing parts are  Some metals can not be
stronger. forged such as cast iron,
 Its offer high ductility. silicon, beryllium,
 More reliable and low cost. iridium.
 Better response to heat  Secondary finishing
treatment. process require.
 Offers broad size range of  The metals gots distorted
products.
if works below the require
 Offer better metallurgical
properties.
temperature.
 Refines structure of metal.
Forging
Forging is done by two processes:

1. Hand forging
2. Machine forging
Hand forging:
The workpiece is heated in the furnace after heating Keep the
heated workpiece (with the support of blacksmith tongs) onto the
anvil and take the hammer are a strike on it, make the required
shape and size.
Machine forging:
In this process, the operation is
performed by the machine but we
(Human) regulate the machines.

Figure: Forging done by machine

Source: Reliance Foundry

https://www.reliance-foundry.com/
blog/forging
Types of forging:
Open Die Hammer or smith
forging:
 In the early days, we use this type of
forging process. This is a very
conventional type of process.
 In this process what we do once we heat
the workpiece to the required
temperature then we put the workpiece
on the anvil by the use of tongs. And
now we strike on it with the use of
hammer for the required shape and size.
 The length of the workpiece decrease
and the crosssection area of the
workpiece increases. This process does
not require any external forging
machine. Done by a human.
Figure: Die forging process
 This is a very simple type of process. Source: Mechanical Booster
https://
www.mechanicalbooster.com
/2020/05/open-die-
Advantages of open Die
forging:

• Better fatigue resistance

and strength.
• Reduces chance of error Source: Shutter Stock
and/or holes. https://
www.shutterstock.com/search/
• Improves microstructure. forging+machine
• Continuous grain flow.
• Finer grain size.
Figures shows open die forging
process.

Source: Technology Student

https://
technologystudent.com/
Open Die Forging
Open Die Forging
Impression Die Drop or
Closed Die forging:
 It gives a more accurate size. In
this, we make a complex shape
like a crank, connecting rod,
wrench, etc.
 To perform the operation we must
have two dies (Upper and lower)
lower is fixed and the upper is
moveable. In this operation, the Figure: Impression Die forging process
workpiece is under the die to
perform the operation as you can Source: The Mechanical Geek
think from the name.
http://
 There might be needed more than
themechanicalgeek.blogspot.com/
2 operations to perform this
2014/07/impression-die-forging.html
process.
Advantages of Impression
Die or Closed Die forging:
• Produces parts up to 25 tons.
• Produces near net shapes that
require only a small amount of
finishing. Source: Ejhadaway
https://ejhadaway.com.au/closed-
• Economic for heavy production. die-forging/
• No materials limitation.
• Better surface finish.
Figure first shows impression die
forging.
Figure second shows parts made
by impression die forging.
Source: Steel Forging
http://www.steelforging.org/
closed-die-forging/
Impression Die Forging
Impression Die Forging
Press forging:
 Press forging may be defined as the
process of shaping a metal that is
placed between two dies by applying
mechanical or hydraulic pressure.
 The press forging is a little faster than
the other two operations because in
this we provide continuous squeezing
action. This is much faster than a
closed die because here only one
squeeze is needed
Source: Mech Talk
 The final object we get from this
process has good smooth, close
https://
tolerance and there is no such problem
www.mechtalk.info/
of alignment of die in this operation.
2019/09/forging-its-
advantages-limitations-
hot.html
Press Forging
Hammer forging:
 With drop forging, also called
hammer forging, the billet is
inserted into the die and hammered
with multiple blows. This process
continues the billet is shaped into
form.
 Drop forging can be operated both at Source: Science Direct
room temperatures, and tongs are https://
generally required. www.sciencedirect.com/
topics/engineering/
Figure first shows hammer forging
drop-hammer
process.
Figure second shows diagrams of all
types of forging.
There are also two major types of forging, those
are:
 Cold forging.
 Hot forging.

Cold forging:
 This is a forging type process in which operation is performed at room
temperature. In cold forging, there is no use of a furnace to heat the
workpiece or too cold the workpiece.
How Cold forging operation performs:
 The machines have two dies and in between the die, we place the workpiece
between them and apply the load on it so as per the shape and size we want
we apply the required forces on it.
 The advantage of clod forging is this is less costly.
Cold Forging
Hot forging:
 The hot forging is performed at extremely high temperatures (up to 1150 °C
for steel, 360-520 °C for al-alloys, 700-800 °C for CU-alloys).
This temperature is necessary because when you perform the operation of hot
forging, the strain hardening problem comes while deforming the workpiece.
 In order to avoid strain hardening problems, you must work between the
temperature as suggested.
 The advantages of hot forging are one good surface finish can be obtained,
and the second improves mechanical properties.
Forging Defects:

The general forging defects are:

 Unfilled sections.
 Cold shut.
 Scale pits.
 Die shift.
 Flakes.
 Improper grain flow.
 Surface cracking.
 Residual stresses.
 Incomplete forging Penetration.
Unfilled sections:
The unfilled section defects can be because of the improper design of
Die or Improver heat treatment of metals .
Cold shut:
Cold shut defects occur in the forging operation when unable to fill the
workpiece at the corner of the complete die.
Scale pits:
The scale fit defects cause low strength of the forging operation
because in these defects the slag or some dust particles are
available in the die and we are not cleaned before the forging
operation so it sticks to the forged metal.
Die shift:
The unfilled section defects can be because of the improper
design of Die or Improper adjustment of Die. To overcome this
defect, we must have a good design of the die.
Flakes:
The flakes defects can cause because of the fast cooled of the upper die which is
unable to makes proper forged operation.
Improper grain flow:
You must have to design a proper die to not to perform such defects.
Surface cracking:
The reason for the defect is the improper temperature provided. To
overcome these defects you must provide the required temperature for
the working metals.
Residual stresses:
The reason for this defect is the fast cooling of improper parts. To
overcome these defects you must do proper and slow cooling of forged
parts.
Incomplete forging Penetration:
While hammering on the workpiece by hand due to improper hammering
this defect generates. To overcome, you must do proper hammering on it.
Any Question?
THANK YOU