Forging of Metals

Forging is a manufacturing process involving the shaping of metal using localized

compressive forces.

Usually the compressive force is in the form of hammer blows using a power hammer or
a press

Forging can produce a piece that is stronger than an equivalent Cast or Machined part

Metal flow and grain structure can be controlled – good strength and toughness – can be
used for highly stresses and critical applications.

Components made are: Forged automobile components include connecting rods,

crankshafts, wheel spindles, axle beams, pistons, gears, and steering arms.

Hand tools, bolts, rivets, turbine shafts and turbine blades, components for machinery and
aircraft
 Forged Components

(a) Schematic illustration of the steps involved in forging a knife. (b) Landing-gear
components for the C5A and C5B transport aircraft, made by forging. (c) General view of a
445 MN (50,000 ton) hydraulic press
 Microstructure as a Function of
Manufacturing Method

Schematic illustration of a part made by three different processes showing grain flow. (a)
Casting (b) Machining and (c) forging.
Each process has its own advantages and limitations regarding external and internal
characteristics, material properties, dimensional accuracy, surface finish, and the economics
of production.
Characteristics of Forging
Forging is carried out in many different ways:

1)By working temperature

2)By impact or gradual pressure used
a) Forging hammer, b) Forging press,
3) By degree to which the flow of the work metal is constrained
by the dies.
a) Open die forging b) Impression die forging (Closed die)
c) Flashless forging
Basic Forging Operations

Upsetting
 Forging Types
1) Smith Forging
2) Drop forging
3) Press forging
4) Machine or Upset forging
Smith Forging Operations available are:
Fullering, Flattening, Bending,
Upsetting and Swaging

Tools available:
Anvil, swage block, Sledge hammer,
tongs,chisel
DROP FORGING
STAGES IN DROP FORGING OF A LEVER
 Impression-Die Forging

(a) through (c) Stages in impression-die forging of a solid round billet. Note the formation
of flash, which is excess metal that is subsequently trimmed off (d) Standard terminology
for various features of a forging die.
 Forging a Rod, Fullering, and Edging

(a) Stages in forging a connecting rod for an internal combustion engine. Note the amount of
flash required to ensure proper filling of the die cavities. (b) Fullering and (c) edging
operations to properly distribute the material when preshaping the blank for forging.
 The Coining
Process

(b)

Schematic illustration of the coining process. The earliest coins were made by open-die
forging and lacked precision and sharp details. (b) An example of a modern coining
operation, showing the workpiece and tooling. Note the detail and superior finish that can be
achieve in this process.
Speed Ranges of Forging Equipment
 FORGING HAMMERS, PRESSES
 Equipment used in forging consists of forging machines, classified as
hammers or presses, and forging dies, which are the special tooling used
in these machines.
 In addition, auxiliary equipment is needed, such as furnaces to heat
the work, mechanical devices to load and unload the work, and trimming
stations to cut away the flash in impression-die forging.

Forging Hammers

Gravity drop hammers Power drop hammers

-- achieve their energy -- accelerate the ram by
by the falling weight of a pressurized air or steam.
heavy ram.
-- The force of the blow is
determined by the height of
the drop and the weight of the
ram
Gravity Drop Hammer
Principles of Various Forging Machines

Schematic illustration of the principles of various forging machines. (a) Mechanical

press with an eccentric drive; the eccentric shaft can be replaced by a crankshaft to
give the up-and-down motion to the ram. (b) Knuckle-joint press. (c) Screw press.
(d) Hydraulic press.
 Forging Presses
Presses apply gradual pressure, rather than sudden impact, to accomplish
the forging operation.
Forging presses include mechanical presses, hydraulic presses, and
screw presses.
Mechanical presses operate by means of eccentrics, cranks, or knuckle
joints
convert the rotating motion of a drive motor into the translation motion of the
ram.
These mechanisms are very similar to those used in stamping presses

Mechanical presses typically achieve very high forces at the bottom of the
forging stroke.
Thus proper setup is essential to avoid breaking the dies

Mechanical presses have high production rates – easier to automate- require

less operator skill
Hydraulic presses use a hydraulically driven piston to actuate the ram.
Large amount of energy can be transmitted to workpies by a constant
load throughout the stroke
Forging takes longer time – the workpiece may cool rapidly unless the
dies are heated
They are slower in operation-involve high initial cost-but maintenance is
lower

Screw presses apply force by a screw mechanism that drives the

vertical ram.
Both screw drive and hydraulic drive operate at relatively low ram
speeds and can provide a constant force throughout the stroke.

These machines are therefore suitable for forging (and other forming)
operations that require a long stroke.
 Forging Defects

Examples of defects in forged parts. (a) Laps formed by web buckling during forging; web
thickness should be increased to avoid this problem. (b) Internal defects caused by an
oversized billet. Die cavities are filled prematurely, and the material at the center flows past
the filled regions as the die closes.