INTRODUCT·ION

Forging is a metal forming manufacturing process

involving the shaping of metal using compressive
forces. The blows are delivered with a hammer
or a die.

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Forging Applications
Forging process is wide ly used in manufacturing .
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industries for producing large numbers of
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prod uct like auto mot ive, aerospace, valve &

fittin gs, handtools & hardware, machine &
equ ipm ent and many more.
ach ined
arts
Why we use Forging
The forging process can create parts that are stronger
than those manufactured by any other metalworking
process like casting. This is why forgings are almost
always used where reliability and human safety are
critical such a airplanes, automobiles, tractors, ships,
oil drilling equipment and engines
The molecular structure of forging part is dancer than
the casting part. ~

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Operations in forging process
FULLERING EDGING ~
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F1M St~ A UpStttlnt
Bend
Classification of Forging
Forging is often classified according to the temperature
at which it is performed : -

Warm Forging

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Types of Forging
1. Smith forging (Open-Die forging) :- This is the
traditional forging operation done openly or in-
openly dies by the village black smith or modern
shop floor by manual hammering or by the power
hammer. The process involves heating the stock in
the black smith hearth and then beating i t over the
anvil. To get the desire shape the operator has to
manipulate the component in between the blows.
The types of operation available are fullering,
flattering, bending , upsetting and swaging.

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 Types of Forging
3. Press forJfn1 :- Similar to the drop forging, the press
forging is also done in closed impression dies with the
expectation that the forcP is continuous squeezing type
applied by the hydraulic press. Rress fon=!;ng dies are similar.
to drop forging dies, the metal is shaped not by means of a
series of blows as in drop forging , but by means of a single
continuous squeezing action. By hydraulic presses, the
material gets uniformly deform through out its entire depth,
the press forging dies use for the various impression, such as
fuller, bender and finisher impression .
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Types of Forging
◄. Machine fcqlna (upset forlina) :- Unlike the press or drop forging where the
material is drawn out, in machine forgfng the material is only upset to get the
desire shape. Originally this was develop for mak1ni bolts head in a continuous
fashion, but now there are fairly large number of diverse.
It is used for making gear blanks, shafts, excels, and sfmilar parts. Upsett1ng
machine called up setter are generally honzontal actmg. The die set consists of
die and correspondina punch or a heading tool. The die consists of two parts, one
called the stationary gripper die which is fixed to the machine frame and the
other movable gripper die which moves along with the die slide of the up setter.
The stock is held between these two gripper dies.
The upset forging cycle start with the, movable die sltdlng against the stationary
die to grip the stock. The two dies when in closed position from the necessary die

filled to the die cavity.

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cavity then the heading tool advance against the stock and upset it to completely
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Types of Forging
5. Roll forging:- It is a process where flat or
round bar stock is reduced in thickness and
increased in length. Roll forming is performed
using two cylindrical rollers each containing
one or more shaped groove as per the job
requirement.
Shapedrol -
Defects in forging
1. Unftlled section or underfUI :- This type of forging
defects left some portion unfilled.

Caused by :-
1. Poor design of die
2. Less raw material
3. Poor heating

Remedies :-
Proper care must be taken on
1. The die design
2. Heating
3. There should be enough raw materials
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Defects in forging
2. Cold Shut :- This type of forging defect occurs as
small cracks at the corners of the object. \. (
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COLD SHUT
Caused by :-
1. Improper design of the forging die
2. Sharp corners of the object
3. Excessive chilling of the forge product

Remedies :-
Proper care must be taken on
1. Fillet radius of the die is to be increased
2. Working temperatl~[t s~ u\'\be "{a\nta_in (,. l-f \ () J () (,. \f
Defects in forging
3. Scale pits:- Scale pit is usual in forging carried out
in open environment, It causes irregular deputations
on the forging surfaces.

Caused by :-
1. This type of forging defect occurs due to improper cleaning of the
forged surface.

Remedies :-
1. This defeel can be avoided by adequate cleaning of for1ed surface y'
Defects in forging
4. Dte shift:- This forging defect 1s caused when the
upper and lower dies are not aligned with each other,
this will lead to improper dimens1ons of the product.

Caused by :-
1. When dies are not aligned with each other.

Remedies:-
1. Th1s defect can be avoided when the die is pro~rly aligned. It can be
done by placing half port,on of the work piece on the upper die and
half on the lower die, so'"ttiat the both pqrtfon can match ( ) ( ~ \
Defects in forging
5. Flakes:- It is internal cracks caused when the
forged products cool quickly, and it reduces the
strength of the forge product.

Caused by :-
1. This type of forging defect occurs due to improper cooling of the forged
product.

Remedies:-
1. Flakes can be avoided when proper cooling is performed
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Defects in forging
6. Surface crackina:- This type of forging defects
arises when the forging operation is performed at low
temperature which leads to occurrence of cracks on
the work pieces.
Cracks

Caused by :-
1. Operating in low temperature

Remedies :-
1. It can be controlled by working o\ a proP!?r temperature I ( )( )'
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Defects in forging
7. Residual stresses in for1ing:- This type of forging
defect takes place when the forged parts are not
properly cooled.

Caused by :-
1. It can be caused by much rapid cooling

Remedies :-
1. It can be prevented by slow cooling of the forged part f

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Defects in forging
8. Incomplete forgina penetration:- Dendritic ingot
structure at the interior of forging is not broken.
Actual forging takes place only at the surface.

Caused by : -
1. Use of light rapid hammer blows

Remedies: -
1. Use forging press for full penetration
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Advantages of Forging
1. Forging is stro nge r than casting
prod ucts ...._.
2. Forgings can be made nea rly any shape,
whic h reduces the need for join ing
mul tiple pieces. Reducing the join t can
imp rove the ove rall stre ngth of the unit
3. Forging is cos t-eff ecti ve when
prod ucti on rate is high
4. Forge parts can be easily welded
Disadvantages of Forging
1. Rapid oxidation occurs due to high
temperature causi ng excess scaling ft
scaling cause wear of die.s
2. The close tolerance in forging parts is
difficult to maintain
3. Initial cost of forging dies ft co.st of
maintenance is high