Forging

forging is the process of converting metal into

desire shape by applying pressure and with or
without heat. When the metal is heated before
applying pressure the process is called hot
forging. In forging metal is heated before below
critical temperature or below molten stage.
Rolling, pressing, Wire drawing etc. is various
types of forging. All sheets, small
component, wire etc are formed by this process.
 Drop forging

Drop forging is a forging process where a hammer

is raised and then "dropped" onto the work piece
to deform it according to the shape of the die.
There are two types of drop forging:

open-die drop forging

closed-die drop forging

 Open-die drop forging

Open-die forging is also known as smith forging. In open-

die forging, a hammer strikes and deforms the workpiece,
which is placed on a stationary anvil. Open-die forging
gets its name from the fact that the dies do not enclose
the work piece allowing it to flow except where contacted
by the dies
 Closed Die Forging

Closed Die Forging is a forging process in

which dies (called tooling) that contain a precut profile of
the desired part move towards each other and covers
the work piece in whole or in part. The heated raw
material, which is approximately the shape or size of the
final forged part, is placed in the bottom die.
 Press forging 

Press forging may be defined as the process of shaping a

metal that is placed between two dies by applying
mechanical or hydraulic pressure. Press forging is usually
done on a forge press - a machine that applies gradual
pressure on the forging dies.
 Hammer forging 

Hammer forging may be defined as a open-die hot forging in which

billet is compressed and deformed by continuous blows of upper die
With the hammer forging process, the material undergoes large
plastic or permanent deformation, resulting in an appreciable change
in shape and cross section
 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 gears etc. 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.
 Advantages of Forging

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 of Forging

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.