FORGING

Presented by –
Rajatabh
Banerjee
 HISTORY OF FORGING

As with the cultural history of man, the history

of metals springs from the land between the
Tigris and the Euphrates,
once called Mesopotamia. The earliest signs of
metalworking date back to about 4500 B.C.

The inhabitants of this fertile valley were the

Sumerians. These people, a mixture of many
ethnic backgrounds, were the true founders of
metallurgy as we know it today.
Forging as an art form started with the desire
to produce decorative objects from precious
metals. Today, forging is a major world-wide
industry that has significantly contributed to the
development of man.
 Post Medieval (1600 )

Post Medieval (1600 ) True use of deliberate cast iron

does not develop untill the introduction of coal as a
smelting fuel in the very late 1500's on the continent
and into the early 1600's in England.

By the time of Jamestown Virginia (1610 +) there are

starting to be small pots available. These were
extremely expensive and limited to the upper class.
Think of the 'witches caldron' shape with three legs,
maybe holding one or two gallons.
 Settlement Era (1700 )

GENERAL use of cast iron-

Cast iron becomes easier to produce and control. It

still is expensive, but prices and availability have
dropped to the point that many families can afford a
SINGLE pot or pan.
 Industrial Age (1820 )

EXTENSIVE use of cast iron-

Cast iron cookware will not become both cheap and

widespread until the introduction of steam powered
technologies. The Victorian period has the largest use
of cast iron for all kinds of objects, from personal goods
to architectureal.
 19th and 20th CENTURY

Forging industry saw a new revolution in the world with wide

use in many of the metalware industry.
 FORGING TERMINOLOGIES

Cold forging:

These include bending, cold drawing, cold heading,

coining extrusion (forward or backward), punching,
thread rolling and others.

Hot forging:

plastically deforming an alloy at a temperature

above its recrystallization point, i.e., high enough
to avoid strain hardening.
Open Die Forgings / Hand Forgings:

Made with repeated blows in an open die,

The operator manipulates the workpiece in
the die.

Impression Die Forgings / Precision

Forgings:

Are further refinements of the blocker

forgings.
The finished part more closely resembles
the die impression.
Anvil

serves as a work bench to the blacksmith, where the

metal to be beaten is placed.
made of cast or wrought iron with a tool steel face
welded on

The flat top has two holes; the wider is called the hardy
hole, where the square shank of the hardy fits.

The smaller hole is called the punch hole, used as

clearance when punching holes in hot metal
ADVANTAGES AND DISADVANTAGES OF
FORGING

ADVANTAGE DISADVANTAGES
• Uniformity of qualities for • High tool cost.
parts subject to high stress
• High tool maintenance.
and loads.
• No weight loss. • Limitation in size and
• Close tolerance. shape.
• Less machining or no
machining in some cases.
• Smooth surface.
• High speed of production.
• Incorporation in welded
structures, i.e., what can
be welded easily.
 HOT FORGING –
ADVANTAGES
• Decrease in yield strength,
therefore it is easier to work
and takes less energy (force).
• Increase in ductility.
• Elevated temperatures
increase diffusion which can
remove or reduce chemical
inhomogeneities.
• Pores may reduce in size or
close completely during
deformation.
DISADVANTAGES
• Undesirable reactions between the
metal and the surrounding
atmosphere (scaling, or rapid
oxidation, of the work piece).
• Less precise tolerances due to
thermal contraction and warping
from uneven cooling.
• Grain structure may vary
throughout the metal for various
reasons.
• Requires a heating unit of some
kind such as a gas or diesel
furnace or an induction heater,
which can be very expensive.
 COLD FORGING –
ADVANTAGES DISADVANTAGES
• No heating required. • Higher forces are required.

• • Heavier and more powerful equipment

Better surface finish. and stronger tooling are required.

• Better reproducibility and • Metal is less ductile.

interchangeability.
• Metal surfaces must be clean and scale-
• Directional properties can be free.
imparted into the metal.
• Intermediate anneals may be required to
• compensate for loss of ductility that
Contamination problems are accompanies strain hardening.
minimized.
• The imparted directional properties may
be detrimental.

• Undesirable residual stress may be

produced.
 Forging applications
FORGING refers to the production of those parts which must be
heated in a closed furnace .
The portion of work in which forging is done is termed as the
forge and the work is mainly performed by the means of
hammers, machines and presses.
Forging processes are among the most important
manufacturing techniques since its used in small tools ,rail road
equipment ,automobile ,aviation sector ,as well as home and
other accessories .

Knives Punching Steel clamps

tool
Forging can be used in home accessories like lamps,
kitchenware and screws .
 Upset or machine forging

Forging of ring and rod types with all kinds of heads such as
bolts,nuts ,washers and collars ,gears etc that can be produced
conveniently in forging machine .

Another application can be

in making gears of various
sizes used in machines .
 Press forging

Press forging is done in presses rather than with

hammers .the action is relatively slow squeezing instead of
delivering heavy blows and penetrates deeply because it
gives metal time to flow .

Towel holders. A hook is there

so that the towel can be hung
 Drop forging
Drop forging is a metal shaping process in which a heated
workpiece is formed by rapid closing of a punch and die
forcing the workpiece to conform to a die cavity. 

A workpiece may be forged by a series of punch and die

operations (or by several cavities in the same die) to
gradually change its shape.  Drop forging is also called
impression die or closed die forging, or rot forging.
Press Forging

Press Forging is a process

whereby slow pressure is
continuously applied to the
area to be shaped. The
pressure extends through the
material which can be either
hot or cold. Cold press forging
is primarily used on thin
materials, while hot press
forging is preferred for larger
work such as parts for trains
and heavy machinery
The pressure necessary to form to steel at forging
temperature varies from about 3000psi(pounds per square
inch) 27,000psi (20 to 190MPa). These pressure are based
on the cross-section area of the forging when measured
across the surface of the die at the parting line
Press capacity is expressed as
P= F/A 2000
P= Pressure required,psi
F= Pressure capacity, tons
A= Area of the forging at the parting line
 Process

Press forging is done in presses rather than with hammers .The

action is relatively slow squeezing of delivering heavy blows and
penetrates deeply because it gives the metal time to flow .Dies
may have less drafts, and the forging comes nearer to the
desired sizes . Pressed forgings are shaped at each impression
with a single smooth stroke and they stick to the die impression
more rigidly . Unless some provision is ,therefore , made the
escape of air and excess die lubricant may be difficult .Thus
press forging dies require a mechanical means for ejecting the
forging are venting for escape of air and lubricant.
 Hydraulic press

Hydraulic press for closed die forging has the same

principle as that of a press for smith or flat die forging
except the construction of the dies
Moreover , they form an integral part of the frame to
maintain accurate alignment of the dies
 Mechanical forging press

Mechanical forging presses of the cranks type have found wide

application in forging practice
The operative units of the press are powered from motor
mounted on the press frame. By means of the v-belt drive,
power is transmitted from pulley to flywheel mounted on the
auxiliary shaft .
The is stopped by the auxiliary brake which is automatically
engaged when the motor is switched off.
Used for the production of rivets, screws ,and nuts where a high
operating speed is desired .
 Material Used

Iron, Copper, Aluminium

Carbon steels, Alloy steels, Stainless steel
Cast aluminum alloys, Wrought aluminum alloys
Cast copper alloys, Wrought copper alloys
Titanium alloys, Magnesium alloys
Polyamides, Polycarbonates
 ADVANTAGES

Press forging can be used to perform all types of forging,

including open-die and impression-die forging.
Impression-die press forging usually requires less draft than
drop forging and has better dimensional accuracy.
Also, press forgings can often be done in one closing of the
dies, allowing for easy automation
Press Forging Beryllium
Copper Billet Press, Puching Press.
Forging
Upset Forging
What is Upset Forging?

Performed on bar stock, upset forging decreases the length of

the stock and increases its cross-section.

High pressures deform the metal and force material into a

designated area of the bar.

The material is shaped into tools such as bolts, pinions,drill

rods, and other objects where high strength is a necessity.

Upset forging refines the mechanical properties by re-

orienting the grain flow to the shape of the tool.

The result is a component which is inherently stronger than

that which has been cast, welded, or machined.
Upset forging is a metal shaping process in which a heated
workpiece of uniform thickness is gripped between split
female dies while a heading die is forced against the
workpiece, deforming and enlarging the need of the
workpiece. 

A sequence of die cavities may be used to control the

workpiece geometry gradually until it achieves its final shape. 
This is a rapid "cold forming" process.
 Process Characteristics

Increases the diameter of the end of the central portion of a

workpiece by compressing its length.

Complex parts are usually formed gradually in a sequence of

separate die cavities.

May produce diameters up to three times the original

diameter.
Impressions may be in the punch die, gripping die, or both.

Usually requires no trimming

May be performed cold on ductile materials.

 Materials Used for Upset Forging

Philadelphia Forgings supplies a wide variety of forgings.

Our forgings are produced from materials such as aluminum

alloy, carbon steel, stainless steel, nickel alloys, Inconel,
titanium alloy, superalloys, and many more.

To see the complete listing of materials or to learn more about

their metallurgical properties, please visit our forging
materials section.
 Benefits of Upset Forgings

The act of upset forging breaks up the cast structure of the

material, aligns the grain flow, and eliminates weaknesses in
the material, such as microshrinkage, gas porosity, and areas
of low density.

Rods, pinions, bolts, and other components created through

upset forging exhibit better levels of strength and soundness.

Upset forged components resist deformation and breakage

during use.

These characteristics make them ideal for applications where

high performance is a must.
Thank you