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Forging Process

The document provides an overview of the metal forging process, detailing its classification by temperature and type, including hot, cold, and various forging methods such as smithy, drop, and press forging. It discusses forgeability, advantages, disadvantages, and common defects associated with forged parts. Additionally, it lists materials that are suitable for forging and outlines the tools used in the process.

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dhanyasuki05
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1 views

Forging Process

The document provides an overview of the metal forging process, detailing its classification by temperature and type, including hot, cold, and various forging methods such as smithy, drop, and press forging. It discusses forgeability, advantages, disadvantages, and common defects associated with forged parts. Additionally, it lists materials that are suitable for forging and outlines the tools used in the process.

Uploaded by

dhanyasuki05
Copyright
© © All Rights Reserved
Available Formats
Download as PPTX, PDF, TXT or read online on Scribd
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METAL FORGING PROCESS

INTRODUCTION
Forging is a manufacturing process
involving the shaping of metal using
localized compressive forces. Forging is
often classified according to the
temperature at which it is performed:
"cold", "warm", or "hot" forging. Forged
parts can range in weight from less than
a kilogram to 580 metric tons.Forged
parts usually require further processing
to achieve a finished part.
FORGEABILITY
The case with which forging is done is called
forgeability. The forgeability of a material can also
be defined as the capacity of a material to undergo
deformation under compression without rupture.
phase, e.g., from ferrite to austenite in steel,
appears or if grain growth becomes excessive.
Metals which have low ductility have reduced
forgeability. The metals having high ductility at
cold working temperature possesses good
forgeability.
Forging Operations

Upsetting Bending Drawing down Cutting

Flattening Fullering Forge Welding Swaging


TYPES OF FORGING
According to working condition :
1. Hot forging
2. Cold forging
According to the working process:

3. Smith forging
4. Drop forging
5. Press forging
6. Impression Die Forging
7. Rolled Forging
SMITHY FORGING
A BLACKSMITH is a smith who works in
iron (so called in English because ‘black
metal’ was a former name for
iron).Smithy forging is a traditional type of
forging used by blacksmith.
This process involves so much hard work
and man-power. Dimentional accuracy is
less in this type of forging. However, unlike
the raw hammering as at an iron forge, a
smith applies directed hammering in order to
form or shape the metal into a certain object.
COMMON HAND FORGING TOOLS

Ton Flatter Swage Fuller Punch


g

Rivet header Hot chisel Hammers Anvil Swage block

Drift Brass scale Brush Heading tool


DROP FORGING
Drop forging is a forging process where a
hammer is raised and then "dropped" onto the
workpiece 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. As the names imply, the difference is in
the shape of the die, with the former not fully
enclosing the workpiece, while the latter does.
PRESS FORGING
Press forging is a method of forging that involves
the slow and continuous application of pressure
on the workpiece. This method differs greatly from
the heavy and quick blows used in drop and
hammer forging. The contact of the workpiece in
the die is measured in seconds whereas drop
forging and hammer forging is measured in
milliseconds. Press forging can be carried out
either hot or cold.
IMPRESSION DIE
FORGING
In the simplest example of impression die forging,
two dies are brought together and the workpiece
undergoes plastic deformation until its enlarged
sides touch the side walls of the die. Then, a small
amount of material begins to flow outside the die
impression forming flash that is gradually thinned.
The flash cools rapidly and presents increased
resistance to deformation and helps build up
pressure inside the bulk of the workpiece that aids
material flow into unfilled impressions.
ROLLED FORGING
Roll forging or roll forming is a forging technique that utilizes
opposing rolls to shape a metal part. Even though roll forging
uses rolls in order to accomplish the deformation of the material,
it is classified as a metal forging process and not a rolling
process. More similarly to metal forging than metal rolling, it is a
discrete process and not a continuous one. Roll forging is usually
performed hot. The precisely shaped geometry of grooves on
the roll, forge the part to the required dimensions. The forging
geometry of the rolls used to forge metal parts is only present
over a portion of the roll's circumference. Only part of a full
revolution of a roll is needed to forge the work piece. Typically in
manufacturing industry, the forging geometry on the rolls may
occupy from one quarter to three quarters of the roll's
circumference.
SOME FORGEBLE MATERIAL

1. Aluminium 2.Magnesium 3.Copper 4. Carbon steels

5.Nickel 6.Titanium 7.Columbium 8.Beryllium


ADVANTAGES OF FORGING
1.Forged parts possess high ductility and offers great resistance to impact
and fatigue
loads.
2. Forging refines the structure of the metal.
3.It results in considerable saving in time, labor and material as compared to the
production of similar item by cutting from a solid stock and then shaping it.
4.Forging distorts the previously created unidirectional fiber as created by rolling
and
increases the strength by setting the direction of grains.
5. Because of intense working, flaws are rarely found, so have good reliability.
6. The reasonable degree of accuracy may be obtained in forging operation.
7. The forged parts can be easily welded.
Disadvantages of Forging
1.Rapid oxidation in forging of metal surface at high temperature results
in scaling which wears the dies.
2. The close tolerances in forging operations are difficult to maintain.
3. Forging is limited to simple shapes and has limitation for parts having
undercuts etc.
4. Some materials are not readily worked by forging.
5. The initial cost of forging dies and the cost of their maintenance is
high.
6.The metals gets cracked or distorted if worked below a specified
temperature limit.
7. The maintenance cost of forging dies is also very high.
DEFECTS IN FORGED PARTS
1. Cold shut
Reasons
Due to improper design of die.
2. Brunt and overheated metal
Reasons
This is caused by improper heating the metal at high temperature or for a long time.
3. Fibred flow lines discontinued
Reasons
This will occur because of very rapid plastic flow of metal.
4. Scale pits
Reason
These are formed by squeezing of scale into the metal surface during forging.
5. Oversize components
Reasons
Due to worn out dies, incorrect dies, misalignment of die halves.

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