FORGING PROCESS

• Forging is the operation where the metal is heated and then a

force is applied to manipulate the metal in such a way that the
required final shape of the metal is obtained. Forging is generally
hot working process though cold working is also used sometimes
• it is also explained as controlled plastic deformation of metals at
elevated temperature to a tune of 1000 degree C into a
predetermined size of shape using compressive forces exerted
through some type of die by a hammer. By definition, forging
involves the shaping of metal by the application of impact load
on preheated metal at which the metal entirely plastic and will
flow under pressure into to the shape of the die .
• Forging Hammer or Hydraulic Forging presses are used for
forging. The forging hammers have a relative high rate of
deformation then the hydraulic presses.
• Since the forging is a hot working process done a elevated
temperatures, the original crystals are deformed and new
crystal with new grain structures are formed and because of
the high temperature many of the impurities are
precipitated .
• The raw material for forging is usually a bar, billet of blank .
• The temperature range of forging plain carbon steels
depends on the percentage of carbon The steels with
carbon content of o.2 % the temperature range is 1150 to
1300 degree C whereas for steels with carbon content of
0.7% the temperature range is 1000 to 1500 degree C
 ADVANTAGES OF FORGING

• The forged components have high strength and ductility and

offers a high resistance to impact and fatigue .
• Forging improves the internal structure of the metal and
hence mechanical properties are also improved .
• Forging renders the parts uniforms in density and
dimensions.
• it permits Weight and cost reduction.
• Forging eliminates porosity of the parts and hence makes its
more strong
 LIMINATIONS OF FORGING

• Initial cost of the Dies and tools and their maintenance is

high.
• Some materials cannot be workable by forging.
• Forging operations is limited to simple shapes. Complicates
shapes of parts cannot be forged. Forging is also limited for
the parts having undercuts and very thin sections, ribs etc.
• Because of elevated temperature, rapid oxidation of metal
surface result oxidation
 FORGING OPERATIONS
• The material available for forging is in the shape of bar of billets.
the formations of the forging shape consists of a combination of
two or more number of relatively simple operations as
• Drawing down or Swaging
• Upsetting
• Punching
• Setting Down
• Bending
• Welding
• Fullering
• Blocking
• Trimming
• Edging
Drawing down of Swaging
• it is the operation of spreading or thinning action and is
accomplished by striking the work with flat dies. Due to
impact of die on metal, its thickness is reduced and length is
increased.
Upsetting
• it is must opposite to Drawing. It involves increasing the cross
sectional area usually by pressing or hammering in the
direction parallel to the original ingot axis. In upsetting
process, the bar of shaft is generally griped indies and the
head or flange done by plain flattened ram of the press.
Punching
• It is the process of producing the holes generally cylindrical
by using a hot punch over a cylindrical die.
Setting downset
• It is a local thinning down operation effected by the set of
hammers. Usually the work is fullered at the place where the
setting down commences.
• Bending
• bending operation is performed by hammering the meta
lover the edge of the anvil or a block of metal held in vice.
This operation Bending is done on the bend parts .
Welding
• Metals like wrought iron ad steels are welded by pressing
together the two surfaces. After they have been raised to the
correct welding temp
Cutting
• In order to perform a rapid cutting operation by chiseling, the
metal is heated to temp of 850 to 9000 degree C and then
hammered blows are directed on the head of the chisel.
Fullering
• This operation is same as setting down and consists of reducing
cross section of the workpiece of lengthening of the stock for
subsequent operation.
Blocking
• it is the term applied to operation of giving and intermediate shape to
the work. It follows fullering and precedes for the final finished shape.
The number of Blocking dies depends upon the size and shape of the
required part.
Trimming
• Trimming is the operation of removing the flash unwanted material
from a forged part. It is usually one by a Press
Edging
• also called PREFORM this stage is required to gather the exact amount
of the material required at each cross section of the finished
component, This the most important stage in forging.
Flat Die Forging
• It is the simplest form of forging wherein the stock is placed
on the anvil and the hammer pressed form its own face
upon he work. The work may be turned either by tongs of
machine called manipulator This operation much depends
upon the skill of the operator. This operation is used for bulky
and simple shaped components
Impression or Closed die forging
• This process is used to forge intricate shaped components'
piece of heated metal is placed on the lower part of the die
block. The metal is forced to take the shape of the die
(Upper and Lower) by blow of a machine called hammer,
 CHARACTERISTICS OF FORGED
PARTS

# It refines the structure of the forged part

# Forged parts have directional properties and hence have
good strength
# Cracks and blow holes in forged pars are minimized or
eliminated
# Mechanical properties are improved
 DEFECTS IN FORGED PARTS
• If the dies are not aligned correctly, mismatch in the surfaces of the forged parts are
observed,
• Defects resulting form the melting, such as dirt slag and blow holes
• Defects resulting from improper heating and cooling forging such as burnt metal
decarburized steels and flakes. Etc
• Defects resulting from improper forging such as cracks etc.
• Unfilled Sections. In this some sections of the die cavity ae not completely filled
• Cold Shut this appears as a small cat the corners of the forging. This is caused mainly by the
improper design of die wherein the proper radius at the corner are not provided and ends up
as a cold shut.
• Scale pits This is seen as irregular depression on the surface of forged parts. This is primarily
caused because of the improper cleaning of the stock used for forging. Oxides and scales
present on the stock surface get embedded in the finished surface
• Die draft this is caused by misalignment of the two die halves making the, two halves of the
forging to improper shape,
• Improper grain flow This is caused by the improper design of the die which makes the flow of
the metal not following the final intended direction,
 METHODS OF FORGING/TYPES OF
FORGING

Here are usually four methods of Forging Generally used:

• Smith Forging
• drop Forging
• Press Forging
• Machine Forging
 SMITH FORGING

• Smith forging is the traditional forging process done openly or in open die by
the villager blacksmiths By manual hammering of power hammering. The
process involves heating the stock in the blacksmiths hearth and then
beating it over the anvil. To get the desired shape, the operator has to
manipulate the component in between the blows. The types of operation
available are as fullering, flattening, bending upsetting and swaging etc.
• In fullering, the material cross section is decreased and length is increased..
to do this the bottom fuller is kept in the anvil with the heated stock over the
fuller, The o fuller is then above the stock and then with the sledge hammer,
the forces is applied on the top fuller.
• After fullering, the stock will gave fuller marks which are removed by
flattening method..