Forging

CONTENTS
 Introduction to Forging
 Why we use Forging
 Classification of Forging
 Forging processes
 Types of Forging
 Operation in Forging process
 Advantages and disadvantages of Forging
 Defects in Forging
 Conclusion
 Introduction to Forging
Forging is a metal forming manufacturing process where raw metal is transformed
into desired shapes and forms through the application of compressive forces. The
process can be performed at a range of temperatures from room temperature to over
1000°C. Forging can also increase the strength of the metal.
 Why we use forging
Strength and Durability
Forged products exhibit exceptional strength and durability due to the compaction and realignment of the metal's internal structure.

Design Flexibility
Forging allows for the creation of complex shapes and geometries that are difficult to achieve through other metalworking methods.

Cost-Effectiveness
Forging is a highly efficient process that minimizes material waste, making it a cost-effective solution for large-scale production.

 This is why forgings are almost always used whose reliability and human safety and critical such as a aeroplane, automobiles, ships, oil
drilling equipment and engines.
 Classification of Forging
 Forging is often classified according to the temperature at which is performed

Hot Forging Warm Forging Cold Forging

 Forging is carried out at above the  Temperature range of warm working is  Forging is carried at or near room
recrystallisation temperature of the above the room temperature but below temperature.
metal. the recrystallisation temperature of metal .  Cold forging is generally preferred
 High strain rates and hence metal  At higher temperature ductility of the when the metal is already soft ,like
can easily deform, less tolling forces metal is increased so required low tolling aluminium.
required. load.  End products requires little or no
 Oxidation and salling occurs , end  End product is with excellent dimensional finishing work and has good surface
product is with poor surface finish , tolerance and surface finish. finish.
less precise tolerances.
Operation in Forging Process
1 Heating
The metal is heated to the appropriate temperature to make it more
malleable and easier to shape.

2 Positioning
The heated metal is carefully positioned on the forging die or
anvil, ready for the compressive force to be applied.

3 Forming
The compressive force, such as a hammer blow or press, is applied
to the metal, shaping it into the desired form.
Types of Forging Processes
Drop Forging Roll Forging
A hammer or press applies a The metal is passed between
single, high-energy blow to the rotating, grooved rolls that
heated metal, shaping it into the gradually shape it into the
desired form. desired cross-section.

Impact Forging Upset Forging

A series of rapid, high-force The metal is compressed axially,
blows are applied to the metal causing it to expand radially and
using a power hammer, creating form the desired shape.
intricate shapes.
Forging Equipment and Tools

Hammers Anvils
Used to apply compressive force to Sturdy metal blocks that provide a
the heated metal during the forging solid surface for the forging
process. operation.

Forges Dies
Furnaces used to heat the metal to the Specially designed tools that shape
desired temperature for forging. the metal into the desired form
during the forging process.
Forging Equipment and Tools
Power Hammers Deliver high-energy blows to the
metal for rapid shaping.

Presses Apply controlled, continuous

force to gradually shape the
metal.

Rolling Mills Gradually shape the metal by

passing it between rotating,
grooved rolls.

Furnaces Heat the metal to the appropriate

temperature for forging.
Applications of Forged Products
Automotive
Forged parts are used in engines, transmissions, and suspension systems,
providing strength and durability.

Aerospace
Forged components are critical in aircraft and spacecraft, where weight,
strength, and reliability are paramount.

Industrial Equipment
Forged parts are used in a wide range of industrial machinery, ensuring
reliable performance under demanding conditions.
Advantages and Disadvantages of Forging
Advantages Disadvantages
• Enhanced Strength and Durability • High Initial Investment in Equipment and Tools
• Improved Metallurgical Properties • Limited to Specific Material Shapes and Sizes
• Design Flexibility • Potential for Waste and Scrap Generation
• Cost-Effectiveness for Large-Scale Production • Skilled Labor Requirement
Conclusion
1 Forging: A Versatile and 2 Continued Importance
Reliable Metalworking and Innovation
Technique
As technology advances, the
Forging has been an essential forging industry continues to
metalworking process for evolve, incorporating new
centuries, producing high- techniques and materials to meet
quality, durable, and the ever-changing demands of
customizable products across a modern manufacturing.
wide range of industries.

3 Bright Future for Forging

With its unparalleled strength, design flexibility, and cost-effectiveness,
forging is poised to remain a vital component of the manufacturing landscape
for years to come.