FORGING

 Process of Forging
 Forging
 Types of Forging
o Hammer Forging (Flat Die)
o Press Forging
o Die Forging
 Forging equipment
o Smith Forging Hamme r
o Board Drop Hamme r
o Forging Press
o Mechanical Forging Press
o Hydraulic Forging Press
 Heat Treatments
o Preheating
o Annealing
o Normalizing
o Hardening
 LISTS OF FORGING MANUFACTURERS
o Forging and Forming Resources
o Forging Industry Association
o Forging Equipment – Johnson Forging Equipment Company
o Forging Equipment – SIFCO Indurtries, Inc. - Forge Group
o Forging Equipment – Delta forging Services, Inc
Process: Forging is a metal forming process used to produce large quantities of
identical parts, as in the manufacture of automobiles, and to improve the mechanical
propertyies of the metal being forged, as in aerospace parts or military equipment. The
design of forged parts is limited when undercuts or cored sections are required. All
cavities must be comparatively straight and largest at the mouth, so that the forging die
may be withdrawn. The products of forging may be tiny or massive and can be made of
steel (automobile axles), brass (water valves), tungsten (rocket nozzles), aluminum
(aircraft structural members), or any other metal. More than two thirds of forging in the
United States is concentrated in four general areas: 30 percent in the aerospace industry,
20 percent in automotive and truck manufacture, 10 percent in off- highway vehicles, and
10 percent in military equipment. This process is also used for coining, but with slow
continuous pushes.

The forging metal forming process has been practiced since the Bronze Age. Hammering
metal by hand can be dated back over 4000 years ago. The purpose, as it still is today,
was to change the shape and/or properties of metal into useful tools. Steel was hammered
into shape and used mostly for carpentry and farming tools. An ax made easy work of
cutting down trees and metal knives were much more efficient than stone cutting tools.
Hunters used metal -pointed spears and ar rows to catch prey. Blacksmiths used a forge
and anvil to create many useful instruments such as horseshoes, nails, wagon tires, and
chains.

Militaries used forged weapons to equip their armies, resulting in many territories being
won and lost with the use and strength of these weapons. Today, forging is used to create
various and sundry things. The operation requires no cutting or shearing, and is merely a
reshaping operation that does not change the volume of the material.

Forging: Forging changes the size and shape, but not the volume, of a part. The change
is made by force applied to the material so that it stretches beyond the yield point. The
force must be strong enough to make the material deform. It must not be so strong,
however, that it destroys the material. The yield point is reached when the material will
reform into a new shape. The point at which the material would be destroyed is called
the fracture point.

In forging, a block of metal is deformed under impact or pressure to form the desired
shape. Cold forging, in which the metal is not heated, is generally limited to relatively
soft metals. Most metals are hot forged; for example, steel is forged at temperatures
o o o o
between 2,100 F and 2,300 F (1,150 C to 1,260 C). These temperatures cause
deformation, in which the grains of the metal elongate and assume a fibrous structure of
increased strength along the direction of flow. (See Figure)

Figure - Flow lines in a forged part

Normally this results in metallurgical soundness and improved mechanical properties.

Strength, toughness, and general durability depend upon the way the grain is placed.
Forgings are somewhat stronger and more ductile along the grain structure than across it.
The feature of greatest importance is that along the grain structure there is a greater
ability to resist shock, wear, and impact than across the grain. Material properties also
depend on the heat-treating process after forging. Slow cooling in air may normalize
workpieces, or they can be quenched in oil and then tempered or reheated to achieve the
desired mechanical properties and to relieve any internal stresses. Good forging practice
makes it possible to control the flow pattern resulting in maximum strength of the
material and the least chances of fatigue failure. These characteristics of forging, as well
as fewer flaws and hidden defects, make it more desirable than some other operations
(i.e. casting) for products that will undergo high stresses.

In forging, the dimensional tolerances that can be held vary based on the size of the
workpiece. The process is capable of producing shapes of 0.5 to >50.0 cm in thickness
and 10 to <100 cm in diameter. The tolerances vary from  /32 in. for small parts to  ¼
1

in. for large forgings. Tolerances of 0.010 in. have been held in some precision forgings,
but the cost associated with such precision is only justified in exceptional cases, such as
some aircraft work.

Types of forging:

Forging is divided into three main methods: hammer, press, and rolled types.

(1) Hammer Forging (Flat Die) : Preferred method for individual forgings. The
shaping of a metal, or other material, by an instantaneous applicatio n of pressure
to a relatively small area. A hammer or ram, delivering intermittent blows to the
section to be forged, applies this pressure. The hammer is dropped from its
maximum height, usually raised by steam or air pressure. Hammer forging can
produce a wide variety of shapes and sizes and, if sufficiently reduced, can create
a high degree of grain refinement at the same time. The disadvantage to this
process is that finish machining is often required, as close dimensional tolerances
cannot be obtained.
 (2) Press Forging : This process is similar to kneading, where a slow continuous
pressure is applied to the area to be forged. The pressure will extend deep into the
material and can be completed either cold or hot. A cold press forging is used on
a thin, annealed material, and a hot press forging is done on large work such as
armor plating, locomotives and heavy machinery. Press Forg ing is more
economical than hammer forging (except when dealing with low production
numbers), and closer tolerances can be obtained. A greater proportion of the
work done is transmitted to the workpiece, differing from that of the hammer
forging operation, where much of the work is absorbed by the machine and
foundation. This method can also be used to produce larger forgings, as there is
no limitation in the size of the machine.

(3) Die Forging: Open and closed die operations can be used in forging. In open-die
forging the dies are either flat or rounded. Large forgings can be formed by successive
applications of force on different parts of the material. Hydraulic presses and forging
machines are both employed in closed die forging. In closed-die forging the metal is
trapped in recessed impressions, which are machined into the top and bottom dies. As
the dies press together, the material is forced to fill
(3) Die Forging Open and closed die operations can be used in forging. In open die
forging the dies are either flat or rounded. Large forgings can be formed by
successive applications of force on different parts of the material. Hydraulic
presses and forging machines are both employed in closed die forging. In closed
die forging the metal is trapped in recessed impressions, which are machined into
the top and bottom dies. As the dies press together, the material is forced to fill
the impressions. Flash, or excess metal, is squeezed out between the dies.
Closed die forging can produce parts with more complex shapes than open die
forging. Die forging is the best method, as far as tolerances that can be met, and
also results in a finished part that is completely filled out and is produced with the
least amount of flashing. The final shape and the improvement in metallurgical
properties are dependent on the skill of the operator. Closer dimensional
tolerances can be held with closed die forgings than with open die forgings and
the operator requires less skill.
the impressions. Flash, or excess metal, is squeezed out between the dies. Closed -die
forging can produce parts with more complex shapes than open -die forging. Die
forging is the best method, as far as tolerances that can be met, and also results in
a finished part that is completely filled out and is produced with the least amount
of flashing. The final shape and the improvement in metallurgical properties are
dependent on the skill of the operator. Closer dimensional tolerances can be held
with closed die forgings than with open die forgings and the operator requires less
skill.

Forging Equipment:

The type of machinery to be used depends on the shape, size, material, and number of
pieces to be made. Forging hammers apply force by the impact of a large ram. This may
be a drop hammer, or weight falling under the force of gravity, or it may be a power
hammer, driven by steam or compressed air. Two types of power hammers are: the smith
forging hammer and the drop hammer. The largest hammers can provide a total force as
high as 80,000 pounds.
 Forging Equipment

The type of machinery to be used depends

on the shape, size, material, and number
of pieces to be made. Forging hammers
apply force by the impact of a large ram.
This may be a drop hammer, or weight
falling under the force of gravity, or it
may be a power hammer, driven by
steam or compressed air. Two types of
power hammers are: the smith forging
hammer and the drop hammer. The
largest hammers can provide a total
force as high as 80,000 pounds.
 Smith Forging Hammer

Heavy workpieces could be processed using a smith forging hammer, and

smaller forgings are die formed in drop hammers. Smith forging
hammers are typically steam or air operated, consisting of a power
actuated ram supported by a heavy cast iron frame. The final product is
a result of the ram being powered into the dies containing the
workpiece.
Board Drop Hammer A drop hammer differs in that the anvil is an integrated
part of the hammer base. It is necessary for the alignment between the
forging die elements used. This method is advantageous in that the
physical properties of the metal are improved by the severe mechanical
working, the operation is rapid, many complicated parts can be forged
to shape, a minimum amount of machining is necessary, and internal
defects are eliminated. The disadvantages are the cost of machinery
and dies, which demands a high quantity of parts to be manufactured in
order for the process to be cost effective.
 Smith Forging Hammer and Board Drop Hammer

  Smith Forging Hammer Heavy workpieces could be processed using a smith-

forging hammer, and smaller forgings are die formed in drop hammers. Smith
forging hammers are typically steam or air-operated, consisting of a power
actuated ram supported by a heavy cast iron frame. The final product is a result
of the ram being powered into the dies containing the workpiece.

  Board Drop HammerA drop hammer differs in that the anvil is an integrated
part of the hammer base. It is necessary for the alignment between the forging die
elements used. This method is advantageous in that the physical properties of the
metal are improved by the severe mechanical working, the operation is rapid,
many complicated parts can be forged to shape, a minimum amount of machining
is necessary, and internal defects are eliminated. The disadvantages are the cost
of machinery and dies, which demands a high quantity of parts to be
manufactured in order for the process to be cost effective.
   Forging Press A forging press consists of a hydraulic press, which exerts a
force capable of pressing steel or a metal alloy into the shape of the forging die.
These machines can be positioned horizontally or vertically. This method can be
used to form car wheels, gears, bushings, and other such parts.

  Mechanical Forging Press Mechanical presses have a motor-driven flywheel

that stores energy to drive a ram-- much lighter than a hammer-- through a crank or
other mechanical device. The ram in a press moves more slowly than a hammer
and squeezes the workpiece. The largest mechanical presses have a total force of
12,000 tons and cannot forge as large or complicated parts as the larger hammers.

  Hydraulic Forging Press Hydraulic presses, in which high-pressure fluid

produced by hydraulic pumps drives a ram, are about 100 times slower than
hammers. They are used for large or complex die forgings and for extrusion.
Presses with a total force of 50,000 tons have been developed in the United States
primarily for the forging of large airplane components. Even larger hydraulic
presses, up to 78,000 tons, have been introduced in Europe.

Heat Treatment:

Materials can be improved before or after manufacturing by different heat treatment

processes. Forging is usually performed to hot metals, allowing for smoother flow and
o
easier deformation. Steel is heated to varying temperatures, usually between 1700 F to
o o
2000 F but can reach as high as 2400 F, depending on the carbon content. Depending on
the amount of work required to the piece, it may be necessary to reheat the piece one or
more times. The temperature of the metal when completely forged is called the finishing
temperature. After forging, the material must be cooled uniformly and prot ected from
moisture or cold air. This is done by placing the material into dry ashes, lime or mica dust
in order to retard the rate of cooling.

:
Forging Press A forging press consists of a hydraulic press, which exerts a force
capable of pressing steel or a metal alloy into the shape of the forging die. These
machines can be positioned horizontally or vertically. This method can be used
to form car wheels, gears, bushings, and other such parts.
Mechanical Forging Press Mechanical presses have a motor driven flywheel that
stores energy to drive a ram in a press moves more slowly than a hammer and
squeezes the workpiece. The largest mechanical presses have a total force of
12,000 tons and cannot forge as large or complicated parts as the larger
hammers.

Hydraulic Forging Press Hydraulic presses, in which high pressure fluid produced by
hydraulic pumps drives a ram, are about 100 times slower than hammers. They
are used for large or complex die forgings and for extrusion. Presses with a total
force of 50,000 tons have been developed in the United States primarily for the
forging of large airplane components. Even larger hydraulic presses, up to
78,000 tons, have been introduced in Europe.