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Upset forging
Updated Tuesday 21st November 2017
A heading tool or ram is positioned perpendicular to the cross sectioned end face of a rod or bar
gripped in a die. On application of pressure, the length of the rod is reduced and the diameter is
increased (upset). This manufacturing process is used extensively in the production of fasteners, to
form bolt heads, screw heads etc.

Horizontal forging
Horizontal forging machines increase the cross-sectional area of a portion of the bar. Forgings are
produced while still attached to the ends of the bar stock. The length of bar to be headed or upset is
heated independently of the machine. The bar is gripped and the moving die forges it to shape.
Electro-upsetting
Electro-upsetters allow large amounts of metal to be gathered. Workpiece (c) is clamped between
electrodes (b) and pressed against anvil electrode (a). An electric current is passed through the end
of the bar, heating it by resistance heating between the electrodes. During the operation
the hydraulic cylinder pushes the bar through the electrodes, causing it to upset.

Manufacture:
1. Upset forging is usually done on horizontal forging machines. Components can also be
upset forged on vertical presses such as hammers and screw presses.
2. Process was originally developed for heading bolt heads, but has been widened to
produce a wide variety of components such as flanged shafts and preforms for finish
forging.
 3. For complex upset forgings a sequence of different-shaped dies may be necessary, the
bar being placed in each die in turn until the forging process is complete. Very often the
end of the bar has to be reheated if large heads are to be formed.
4. Process tends to be slow and manual operation quickly causes fatigue.
Production rates 80–150 h-1. After each forging, the component is hot cropped off the end
of the bar and is replaced in the slot heater or induction heater to reheat the end of the bar.
Several bars might be reheating at once.
5. Machine sizes range from 75 tons (for 25 mm dia. bar) to 1250 tons (for 125 mm dia. bar).
6. Electro-upsetters are more efficient in heating only the length of bar required, and can
produce increased upset cross sections. Preforms may be finally forged on screw presses.
Two electro-upsetters or an automatic upsetter might be required to match the screw press
forging rate.

Materials:
1. Most materials that can be hot forged can be upset forged. The exception is copper, which
can not be electro-upset because of low electrical resistivity which leads to inadequate
heating.
2. Aluminium alloys are also difficult to electro-upset, especially those alloys with narrow
freezing ranges (small solidus-liquidus temperature range).
3. Electro-upsetters require bar stock with a smooth surface finish because the bars must
slide between the electrodes and maintain good electrical contact (a maximum surface
roughness of 0.02 mm is essential). Drawn or peeled bar is preferred. Steel black bar is
unsuitable for electro-upsetting.

Design:
1. The length (L) (shown in the first figure) of unsupported metal, which can be upset at one
stroke without risk of serious buckling, must not be more than three times the diameter of
the bar (d). In practice L is usually kept below 2.5d.
2. Where the length (L) of unsupported metal is not greater than three times the diameter (d)
of the bar, the maximum increase in cross section, obtainable at a single stroke, is 1.5
times the diameter of the bar (d). Again, in practice a lower figure of 1.4d is generally used.
3. Longer lengths of upset than 3d can be formed, but require a recess in the heading tool.
The recess will need to be tapered to allow ejection of the heading tool.
4. Finished bolt head forgings can be produced in conjunction with final forging in closed dies
on screw presses.

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Production Engineering

What is Forging Process, Operation, Types, Application,

Advantages and Disadvantages?
April 24, 2017 Admin 1 Comment forging, Metal Forming Process, types

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Today we will learn about what is forging and types of forging. Further we will discuss about operation,
application, advantages and disadvantages of this process. Forging is a metal forming process in which
the metal is heated and a force is applied in such a way that a required shape can be obtain. It is
basically a hot working process in which the work piece is heated up to plastic stage and the force is
applied by manually or by press according to the requirement. This force is compressive in nature which
is basic requirement of forging. Sometime forging operation is done without application of heat known
as cold forging. Now days, Forging is used in every manufacturing industries.
What is Forging Process?
Operation:
Mainly forging consist two operations according to the force applied.
1.) Drawing Down:
Drawing down is a process of elongate the length and reduce the cross section area of work piece.
Simply in this operation, the length of work piece increases and the cross section area decreases. In this
process, a compressive force is applied at perpendicular direction of its length axis. If a tensile force is
applied to change its length at parallel to its length axis, this process is known as wire drawing.

2.) Upsetting:
Upsetting is just opposite operation to drawing down. In this operation, the length of work piece
decreases and its cross section area increases. In this process, a compressive force is applied at parallel
direction to its length axis.
Types of Forging:
Forging may be classified into following ways.

1.) According to the Temperature:

a.) Hot Forging:

If the work piece is heated above its recrystallization temperature and then force is applied, the process
is known as hot forging. The recrystallization temperature of most of metals is half of its melting
temperature.

b.) Warm Forging:

Warm forging done at the temperature about 40 percent of its melting point temperature.
c.) Cold Forging:

Cold forging is done at room temperature. This process gives highest mechanical properties among all
forging processes.

2.) According to arrangement of Die:

a.) Open Die Forging:

This forging process uses flat dies or no die. This is mostly hot forging process in which the work piece
heated and hammered to obtain desire shape. This process produce rough product.

b.) Close Die Forging:

Close die forging is a process in which a set of impression die is used to produce desire shape on work
piece. Mostly these products do not need any finishing process. This process required higher force.

3.) According to the Forging equipment:

a.) Smith forging:

Smith forging is traditional method of metal forming. It is open die forging method in which the work
piece is placed on a stationary anvil and a hammer strikes and deform the work piece. The force is
applied either by manually or power hammers.

b.) Drop Forging:

Drop forging is done in closed impression dies. An automatic

hammer applied the force in series of blow by dropping action. In this type, a sudden applied force is
used.

c.) Press Forging:

Press forging is similar to drop forging except it uses continuous squeezing type applied force by the
hydraulic press. This process increase the length and decrease its cross section of work piece.
 d.) Machine Forging:

Machining forging is an upsetting process in which the cross section of work piece increases and length
decreases.

Advantages and Disadvantages:

Advantages:
 Forging gives comparatively tougher product compare to casting.
 The fatigue strength and creep resistance of forge product is higher.
 Forge product has higher mechanical properties.
 Low cost operation.
 This process does not required special skill operator.
 Variety of shapes can be formed by this process.

Disadvantages:
 Higher initial cost for big forging presses.
 Secondary finishing process required in hot forging.
 It cannot produce complex shapes.
 Size is limited due to size of press.
 Brittle metal cannot be forged.

Application of Forging:
 Mainly forged products are used in every mechanical industry.
 Turbine rotor, generator rotor etc. are forged product.
 It gives higher fatigue strength so most of moving parts like crankshaft, camshaft gearsetc. are made by
forging operation.
 Cold forging is used to produce chisel, bolts etc.
 These are mostly used in hand tools and hardware manufacturing.
 It is used in ship building in various structure works.

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One thought on “What is Forging Process, Operation,

Types, Application, Advantages and Disadvantages?”

sam

August 2, 2019 at 10:29 pm

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it was helpful, thanks

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Forging operations
Forging operations:
1: Drawing:
This is the operation in which metal gets elongated with a reduction in the cross
sedation area. For this, a force is to be applied in a direction perpendiaulant to
the length axis.
2:Up setting:
This is applied to increase the cross seat ional area of the stock at the expanse of
the length. To achieve the length of upsetting force is applied in a direction
parallel to the length axis, For example forming of a bolt head.

3:Fullering:
It a similar to material cross-section is decreased and length increased. To do this;
the bottom fuller is kept in angle hole with the heated stock over the fuller .the
top fuller is then kept above the stock and then with the sledge hammer, and the
force is applied on the top fuller.
4:Edging:
It is a process in which the metal piece is displaced to the desired shape by
striking between two dies edging is frequently as primary drop forging operation.

5:Bending:
Bending is very common forging operation. It is an operation to give a turn to
metal rod or plate. This is required for those which have bends shapes.
6:Punching:
It is a process of producing holes in motel plate is placed over the hollow
cylindrical die. By pressing the punch over the plate the hole is made.

7:Forged
welding:
It is a process of joining two metal pieces to
increase the length. By the pressing or hammering then when they are at for ging
temperature.Itis performed in forging shop and hence is called forged welding.

8:Cutting:
It is a process in which a metal rod or plate cut out into two pieces, with the help
of chisel and hammer, when the metal is in red hot condition.

9:Flating and setting down:

Fullering leaves a corrugated surface on the job. Even after a job is forged into
shape with a hammer, the marks of the hammer remains on the upper surface of
the job. To remove hammer marks and corrugation and in order to obtain a
smooth surface on the job, a flatter or set hammer is used.

10: Swaging:
Swaging is done to reduce and finish work for desire size and shape, usually either
round or hexagonal. For small jobs top and bottom swage pair is employed,
where as for large work swage block can be used.
Types of Forging Processes
Definition of forging

Forging is defined as a metal working process that shape workpiece into desired dimensions by
compressive forces applied through the use of dies and tools. Forging process is operated by
hammering or pressing the metal. It is one of the oldest known metalworking processes with its
origin about some thousands of years ago. At first,forging was complicated by a smith using hammer
and anvil. Using hammer and anvil is a crude form of forging. The smithy or forge has been
improved to become a facility with engineered processes, production equipment, tooling, raw
materials and products to meet the demands of modern industry.

In nowadays, industrial forging is done either with presses or hammers powered by compressed air,
electricity, hydraulics or steam. Some examples of products obtained by forging process are-
crane hook, connecting rod of an IC engine, spanner, gear blanks, crown wheel, pinion, etc.

Forging process produces parts of superior mechanical properties with minimum waste of material.
In this process,the starting material has a relatively simple geometry; this material is plastically
deformed in one or more operations into a product of relatively complex configuration. Forging
usually requires relatively expensive tooling. Thus, the process is economically attractive when a
large number of parts must be produced and/or when the mechanical properties required in the
finished product can be obtained only by a forging process.

Although forging shows superior quality product compared to other metal manufacturing processes
(casting, welding, machining, ect), there are still some defects that may lightly happen if a proper
care is not taken in forging process design, defects can be defined as the imperfections that exceed
certain limits. There are many imperfections that can be considered as being defects, ranging from
those traceable to the starting materials to those caused by one of the forging processes or by post
forging operations. Like drop forging, we could also see some drop forging defects in whole
process.

Types of Forging Processes

When forging,an initially simple part- a billet, is plastically deformed between two dies to obtain the
desired final configuration. For understanding and optimization of forging operations, it is useful to
classify this process in a systematic way. There are a large number of forging processes that can be
classified as follows:

1) Types According to The Temperature of The Workpiece (cold forging vs warm forging vs
hot forging)
a) Cold forging: Forging is carried out at or near room temperature (below the recrystallization temp.)
of the metal.Carbon and standard alloy steels are most commonly coldforged.Cold forging is
generally preferr yued when the metal is already a soft, like aluminum. This process is usually less
expensive than hot forging and the end product requires little or no finishing work. Cold forging is
also less susceptible to contamination problems, and the final component features a better overall
surface finish.

Advantages: Production rates are very high with exceptional die life, Improves mechanical
properties, Less friction between die surface and work piece, Lubrication is easy, No oxidation or
scaling on the work.

Disadvantages: Residual stress may occur,Heavier and more powerful equipment is

needed,Stronger tooling is required,Tool design and manufacturing are critical.

b) Warm forging:The temperature range for the warm forging of steel runs from above room
temperature to below the recrystallization temperature.Compared with cold forging, warm forging
has the potential advantages of:Reduced tooling loads,reduced press loads, increased steel ductility,
elimination of need to anneal prior to forging, and favorable as-forged properties that can eliminate
heat treatment.In warm forging, the billet is heated below the recrystallization temperature, up to 700
to 800 0C for steels, in order to lower the flow stress and the forging pressures.

Advantages:High production rates,Excellent dimensional tolerances and surface finish for forged
parts,Significant savings in material and machining,Favorable grain flow to improve
strength,Greater toughness of the forged part.

c) Hot forging (most widely used): Forging is carried out at a temperature above the recrystallization
temperature of the metal.The recrystallization temperature is defined as the temperature at which
the new grains are formed in the metal. This kind of extreme heat is necessary in avoiding strain
hardening of the metal during deformation.

Advantages: High strain rates and hence easy flow of the metal, recrystallization and recovery are
possible, forces required are less.

Disadvantages: Lubrication is difficult at high temperatures, oxidation and scaling occur on the work
piece, poor surface finish, less precise tolerances, possible warping of the materialduring the
cooling process.
2) Types According to Arrangements of Dies

a) Open-die forging: Forging in which the flat dies of simple shape are used to allow the material to
freely deformed in lateral directions of applied load. Below shows open-die forging operation.
Features: open die forging is only suitale for simple shapes for its less dimensional accuracy, there
is high requires on the skill of operators, the dies of open die forgings are simple and less expensive,
which is simplest of all the forging operations.

b) Closed-die forging (also called impression die forging): Forging in which the material is fully
constrained in the cavity created by the upper and lower die halves. It allows more accurately
shaped parts to be formed,higher interface pressures required,requires very accurate control of
material volume and proper die design. Closed-die forging is a form of impression-die forging,which
does not depend on flash formation to achieve complete filling of the die. Material is deformed in a
cavity that allows little or no escape of excess material, thus placing greater demands on die design.

Features: Work is rough forged close to final shape by blocking die, work is forged to final shape and
dimensions by finishing die, both blocking die and finishing die are machined into the same die
block, more number of dies are required depending on the complexity of the job, two die halves
close-in and work is deformed under high pressure,high dimensional accuracy/close control on
tolerances, suitable for complex shapes, dies are complex and more expensive,large production
rates are necessary to justify high costs.
See differences between open die forging&closed die forging...

Die design parameters: Die design depends on the knowledge of strength and ductility of work piece
material, sensitivity of material to the rate of deformation and temperature, frictional characteristics,
shape and complexity of work piece, die distortion under high forging loads.

Die material requirements: Strength and toughness at elevated temperature, Hardenability and
ability to harden uniformly, Resistance to mechanical and thermal shocks, Wear resistanceto resist
abrasion wear due to scales present on work piece.

Selection of proper die material depends on: die size, composition and properties of work piece,
complexity of shape No. of performing steps, forging temperature, type of forging operation, cost of
die material, No. of forgings required, heat transfer from work piece to dies, etc.

Die materials used: tool and die steels with Cr, Ni, Mo,
Va.
3)Types According to Forging Equipments

Forged components are shaped either by a hammer or press. Forging on the hammer is carried out
in a succession of die impressions using repeated blows. The quality of the forging,and the economy
and productivity of the hammer process depend upon the tooling and the skill of the operator. In
press forging, the stock is usually hit only once in each die impression and the design of each
impression becomes more important while operator skill is less critical. The continuous development
of forging technology requires a sound and fundamental understanding of equipment capabilities
and characteristics. The equipment i.e. presses and hammers used in forging, influences the forging
process, since it affects the deformation rate and temperature conditions, and it determines the rate
of production. The requirements of a given forging process must be compatible with the load,
energy, time, and accuracy characteristics of a given forging machine.

1) Hammer forging: The most common type of forging equipment is the hammer and anvil. The
hammer is the least expensive and most versatile type of equipment for generating load and energy
to carry out a forging process. This technology is characterized by multiple impact blows between
contoured dies. Hammers are primarily used for hot forging. There are basically two types of anvil
hammers: Gravity-drop hammers and power drop hammers. In a simple gravity-drop hammer, the
upper ram is connected to a board (board-drop hammer), a belt (belt-drop hammer), a chain (chain-
drop hammer),or a piston (oil-, air-, or steam-lift drop hammer).The ram is lifted to a certain height
and then dropped on the stock placed on the anvil. During the down stroke, the ram is accelerated
by gravity and builds up the blow energy. The upstroke takes place immediately after the blow. The
operation principle of a power-drop hammer is similar to that ofan air-drop hammer. In the down
stroke, in addition to gravity,the ram is accelerated by steam, cold air, or hot air pressure. In the
power-drop hammer, the acceleration of the ram is enhancedwith air pressure applied on the top
side of the ram cylinder. Figure 3 shows mechanical board hammer- It is a stroke restricted machine.
Repeatedly the board (weight) is raised by friction rolls and is dropped on the die. Its rating is in the
terms of weight of the ram and energy delivered. Figure 4 shows steam hammer- It uses steam in a
piston and cylinder arrangement. It has greater forging capacity. It can produce forgings ranging
from a few kgs to several tones. It is preferred in closed-die forging.
2) Press forging: In press forging, the metal is shaped not by means of a series of blows as in
hammer forging, but by means of a single continuous squeezing action. There are two main
types:mechanical and hydraulic presses. Mechanical presses function by using cams, cranks and/or
toggles to produce a preset (a predetermined force at a certain location in the stroke) and
reproducible stroke. Due to the nature of this type of system,different forces are available at different
stroke positions. Mechanical presses are faster than their hydraulic counterparts (up to 50 strokes
per minute). Their capacities range from 3 to 160 MN (300 to 18,000 short tons-force). Hydraulic
presses use fluid pressure and a piston to generate force. Figure 5 shows hydraulic press.It is a load
restricted machine. It has more of squeezing action than hammering action. Hence dies can be
smaller and have longer life than with a hammer. Features of Hydraulic Press: Full press load is
available during the full stroke of the ram, ram velocity can be controlled and varied during the
stroke, it is a slow speed machine and hence has longer contact time and hence higher die
temperatures, the slow squeezing action gives close tolerance on forgings, initial cost is higher
compared to hammers. The advantages of a hydraulic press over a mechanical press are its
flexibility and greater capacity. The disadvantages include a slower, larger, and costlier machine
to operate.
 Types of Forging
Processes
There are basically three methods (or processes) to make a forged part.

1. Impression Die Forging

2. Cold Forging

3. Open Die Forging

4. Seamless Rolled Ring Forging

Impression Die Forging

Impression die forging pounds or presses metal between two dies (called tooling) that contain a precut
profile of the desired part. Parts from a few ounces to 60,000 lbs. can be made using this process. Some
of the smaller parts are actually forged cold.

PROCESS OPERATIONS

Graphical depiction of process steps.

 Still Graphic
 Animated Sequence
 Video
Process Capabilities
Commonly referred to as closed-die forging, impression-die forging of steel, aluminum, titanium and
other alloys can produce an almost limitless variety of 3-D shapes that range in weight from mere
ounces up to more than 25 tons. Impression-die forgings are routinely produced on hydraulic presses,
mechanical presses and hammers, with capacities up to 50,000 tons, 20,000 tons and 50,000 lbs.
respectively.
As the name implies, two or more dies containing impressions of the part shape are brought together as
forging stock undergoes plastic deformation. Because metal flow is restricted by the die contours, this
process can yield more complex shapes and closer tolerances than open-die forging processes.
Additional flexibility in forming both symmetrical and non- symmetrical shapes comes from various
preforming operations (sometimes bending) prior to forging in finisher dies.

Part geometry's range from some of the easiest to forge simple spherical shapes, block-like rectangular
solids, and disc-like configurations to the most intricate components with thin and long sections that
incorporate thin webs and relatively high vertical projections like ribs and bosses. Although many parts
are generally symmetrical, others incorporate all sorts of design elements (flanges, protrusions, holes,
cavities, pockets, etc.) that combine to make the forging very non-symmetrical. In addition, parts can be
bent or curved in one or several planes, whether they are basically longitudinal, equidimensional or flat.

Most engineering metals and alloys can be forged via conventional impression-die processes, among
them: carbon and alloy steels, tool steels, and stainless, aluminum and copper alloys, and certain
titanium alloys. Strain-rate and temperature-sensitive materials (magnesium, highly alloyed nickel-based
superalloys, refractory alloys and some titanium alloys) may require more sophisticated forging
processes and/or special equipment for forging in impression dies.

Back To Top

Cold Forging
Most forging is done as hot work, at temperatures up to 2300 degrees F, however, a variation of
impression die forging is cold forging. Cold forging encompasses many processes -- bending, cold
drawing, cold heading, coining, extrusions and more, to yield a diverse range of part shapes. The
temperature of metals being cold forged may range from room temperature to several hundred
degrees.

Process Operations
Graphical depiction of process steps.

Process Capabilities

Cold forging encompasses many processes bending, cold drawing, cold heading, coining, extrusion,
punching, thread rolling and more to yield a diverse range of part shapes. These include various shaft-
like components, cup-shaped geometry's, hollow parts with stems and shafts, all kinds of upset (headed)
and bent configurations, as well as combinations.

Most recently, parts with radial flow like round configurations with center flanges, rectangular parts, and
non-axisymmetric parts with 3- and 6-fold symmetry have been produced by warm extrusion. With cold
forging of steel rod, wire, or bar, shaft-like parts with 3-plane bends and headed design features are not
uncommon.

Typical parts are most cost-effective in the range of 10 lbs. or less; symmetrical parts up to 7 lbs. readily
lend themselves to automated processing. Material options range form lower-alloy and carbon steels to
300 and 400 series stainless, selected aluminum alloys, brass and bronze.

There are times when warm forging practices are selected over cold forging especially for higher carbon
grades of steel or where in-process anneals can be eliminated.

Often chosen for integral design features such as built-in flanges and bosses, cold forgings are frequently
used in automotive steering and suspension parts, antilock-braking systems, hardware, defense
components, and other applications where high strength, close tolerances and volume production make
them an economical choice.

In the process, a chemically lubricated bar slug is forced into a closed die under extreme pressure. The
unheated metal thus flows into the desired shape. As shown, forward extrusion involves steel flow in
the direction of the ram force. It is used when the diameter of the bar is to be decreased and the length
increased. Backward extrusion, where the metal flows opposite to the ram force, generates hollow
parts. In upsetting, the metal flows at right angles to the ram force, increasing diameter and reducing
length.

Back To Top
 Open Die Forging
Open die forging is performed between flat dies with no precut profiles is the dies. Movement of the work
piece is the key to this method. Larger parts over 200,000 lbs. and 80 feet in length can be hammered or
pressed into shape this way.

PROCESS OPERATIONS

Graphical depiction of process steps.

 Still Graphic
 Animated Sequence
 Video
Process Capabilities
Open-die forging can produce forgings from a few pounds up to more than 150 tons. Called open-die
because the metal is not confined laterally by impression dies during forging, this process progressively
works the starting stock into the desired shape, most commonly between flat-faced dies. In practice,
open-die forging comprises many process variations, permitting an extremely broad range of shapes and
sizes to be produced. In fact, when design criteria dictate optimum structural integrity for a huge metal
component, the sheer size capability of open-die forging makes it the clear process choice over non-
forging alternatives. At the high end of the size range, open-die forgings are limited only by the size of
the starting stock, namely, the largest ingot that can be cast.

Practically all forgeable ferrous and non-ferrous alloys can be open-die forged, including some exotic
materials like age-hardening superalloys and corrosion-resistant refractory alloys.

Open-die shape capability is indeed wide in latitude. In addition to round, square, rectangular, hexagonal
bars and other basic shapes, open-die processes can produce:

 Step shafts solid shafts (spindles or rotors) whose diameter increases or decreases (steps down) at
multiple locations along the longitudinal axis.
 Hollows cylindrical in shape, usually with length much greater than the diameter of the part. Length, wall
thickness, ID and OD can be varied as needed.
 Ring-like parts can resemble washers or approach hollow cylinders in shape, depending on the
height/wall thickness ratio.
 Contour-formed metal shells like pressure vessels, which may incorporate extruded nozzles and other
design features.

Not unlike successive forging operations in a sequence of dies, multiple open-die forging operations can
be combined to produce the required shape. At the same time, these forging methods can be tailored to
attain the proper amount of total deformation and optimum grain-flow structure, thereby maximizing
 property enhancement and ultimate performance for a particular application. Forging an integral gear
blank and hub, for example, may entail multiple drawing or solid forging operations, then upsetting.
Similarly, blanks for rings may be prepared by upsetting an ingot, then piercing the center, prior to
forging the ring.

Back To Top

Seamless Rolled Ring Forging

Seamless rolled ring forging is typically performed by punching a hole in a thick, round piece of metal
(creating a donut shape), and then rolling and squeezing (or in some cases, pounding) the donut into a
thin ring. Ring diameters can be anywhere from a few inches to 30 feet.

PROCESS OPERATIONS

Graphical depiction of process steps.

 Still Graphic
 Animated Sequence
 Video
Process Capabilities
Rings forged by the seamless ring rolling process can weigh < 1 lb up to 350,000 lbs., while O.D.’s range
from just a few inches up to 30-ft. in diameter. Performance-wise, there is no equal for forged, circular-
cross-section rings used in energy generation, mining, aerospace, off-highway equipment and other
critical applications.

Seamless ring configurations can be flat (like a washer), or feature higher vertical walls (approximating a
hollow cylindrical section). Heights of rolled rings range from less than an inch up to more than 9 ft.
Depending on the equipment utilized, wall-thickness/height ratios of rings typically range from 1:16 up
to 16:1, although greater proportions have been achieved with special processing. In fact, seamless
tubes up to 48-in. diameter and over 20-ft long are extruded on 20 to 30,000-ton forging presses.

Even though basic shapes with rectangular cross-sections are the norm, rings featuring complex,
functional cross- sections can be forged to meet virtually any design requirements. Aptly named, these
contoured rolled rings can be produced in thousands of different shapes with contours on the inside
and/or outside diameters. A key advantage to contoured rings is a significant reduction in machining
operations. Not surprisingly, custom-contoured rings can result in cost-saving part consolidations.
Compared to flat-faced seamless rolled rings, maximum dimensions (face heights and O.D.’s) of
contoured rolled rings are somewhat lower, but are still very impressive in size.

High tangential strength and ductility make forged rings well-suited for torque- and pressure-resistant
components, such as gears, engine bearings for aircraft, wheel bearings, couplings, rotor spacers, sealed
discs and cases, flanges, pressure vessels and valve bodies. Materials include not only carbon and alloy
steels, but also non-ferrous alloys of aluminum, copper and titanium, as well as nickel-base alloys.