Forging – The process

 Metal forging is a metal forming process that involves applying

compressive forces to a work piece to deform it, and create a desired
geometric change to the material.

 It is the process of shaping heated metal by the application of sudden

blows or steady pressure and makes use of the characteristics of
plasticity of material.

 Application of heat lowers the yield point and makes deformation

easier.

 Smithy is the best example for Forging.

Forging Products
 Classification of Metal Forging Process
By the degree to which the flow of material is constrained -

1. Open die forging - In which the work is compressed between two

die that do not constrain the metal during the process.

2. Impression die forging / Closed Die forging - In which cavities

within the die restrict metal flow during the compression of the part,
causing the material to deform into a desired geometric shape.

Some material in impression die forging is not constrained by the

cavities and flows outward from the die, this metal is called flash. In
industrial metal forging, a subsequent trimming operation will be
performed to remove the flash.
Closed and open die forging processes

Open- Die Forging

Closed- Die Forging

Impression- Die Forging

 Classification of Closed Die Forging
1) Drop Forging
2) Press Forging
 Classification of Closed Die Forging
1) Drop Forging

In this process, the forging is made by hammering a heated bar or billet

into aligned die cavities by allowing the ram to drop using Gravity

The forging equipment used for this is “Drop hammer”

Types of Drop hammer are –

1) Steam – air drop hammer

2) Board drop hammer
3) Belt drop hammer
4) Rope drop hammer
5) Chain drop hammer
 2. Press Forging
• In press forging, the pressure is applied on the heated billet continuously

• Parts are made by plastically deforming a metal into die-cavities by a

slow squeezing action

• The presses used for press forging are-

Mechanical press (Crank, eccentric, knuckle or screw)
Upright hydraulic press
 Forging Defects

 Buckling, in upsetting forging - Subject to high compressive stress.

 Surface cracking - due to temperature differential between surface and

centre, or excessive working of the surface at too low temperature.

 Micro cracking - due to residual stress.

 Flakes : internal rapture caused by improper cooling.
 Forging Defects
Pitting - Caused by scale, which if not removed thoroughly from the die cavities is
worked into the surface of the forging.

Remedies – Frequent cleaning of dies

Die shift – Caused by misalignment between the top and bottom forging dies

Incomplete filling of the die – Caused by – wrong amount of metal, insufficient

number of blows during forging, forging the stock at too low temperature when it
has lost its plasticity

Hot tears and thermal cracking: these are surface cracks occurring due to non
uniform cooling from the forging stage or during heat treatment.