MALAWI UNIVERSITY OF BUSINESS AND
APPLIED SCIENCES
SCHOOL OF ENGINEERING
MECHANICAL ENGINEERING DEPARTMENT
Manufacturing Technology and Processes
(Fundamentals of Machining - Forging)
Forging
Lesson objectives
By the end of this lesson, students will be able to:
1. Define forging,
2. Classify metal forging methods,
3. Describe the forging process in each classification,
4. State forging operations,
5. State applications for each forging process,
6. Describe defects observed from the forging processes,
7. State remedies to tackle defects in forging processes,
8. State tools/accessories used in forging opearions.
Forging
1. This is a process in which metal deforms plastically to another required shape and
size with the help of hand hammering or machine pressing at a certain
temperature.
2. It is one of the oldest metalworking arts with its origin about some thousands of
years back.
3. Some examples of shapes obtained by forging process: Crane hook, connecting rod
of IC engine, spanner, gear blanks, etc.
Classification of forging
• Classification of forging process can either be based on:
1. Forging temperature, or
2. Arrangement of dies, or
3. Forging equipment
Classification based on forging temperature
• There are also two major types of forging, those are:
1. Hot forging
2. Cold forging
Hot forging
• Forging is carried out at a temperature above the recrystallization temperature of
the metal.
Advantages of hot forging
• High strain rates and hence easy flow of the metal
• Recrystallization and recovery are possible
• Forces required are less
Disadvantages of hot forging
• Lubrication is difficult at high temperatures
• Oxidation and scaling occur on the work
• Poor surface finish
• Dies must withstand high working temperature
Cold forging
• Forging is carried out at a temperature below the recrystallization temperature of
the metal.
Advantages of cold forging
• Less friction between die surface and work piece
• Lubrication is easy
• No oxidation or scaling on the work
• Good surface finish
Disadvantages of cold forging
• Low strain rates, hence less reduction per pass.
• Recrystallization and recovery do not occur.
• Hence, annealing is required for further deformation in subsequent cycles.
• Forces required are high.
Classification based on arrangement of dies
• Classification of forging process can either be based on:
1. Open die forging
2. Closed die forging
Open die forging
• Open die forging (also known as free forging) is the process of
deforming a piece of metal between multiple dies that do not
completely enclose the material.
• The metal is altered as the dies “hammer” or “stamp” the
material through a series of movements until the desired
shape is achieved.
• Products formed through open forging often need secondary
machining and refining to achieve the tolerances required for
the finished specifications.
• Open die forging is widely used for the products in small
quantity that are simple, rather than complex.
• Custom shapes can also be produced with open die forging.
• The strength of the grain structure will be increased during the
deformation process due to the repeated working of the steel
billet.
• Another benefit of open die forging is that the fatigue
resistance and strength of products will be improved.
• Besides, voids could be effectively reduced after open die
forging.
Closed die forging
• Closed die forging (also known as impression die forging)
is a metal forming process that compress a piece of metal
under high pressure to fill an enclosed die impression.
• For some special shapes, second forging operation is
required to reach final shapes and dimensions.
• The type of material, tightness of tolerances, and need for
heat treatment can determine the cost of a closed die
forged part.
• For closed die forging, the molding dies are first precision
machined and cost is high.
• The metal bars are then placed on between upper and
lower dies and forged to any shapes needed.
• After closed die forging very less or no machining will be
operated due to its high accuracy throughout the process.
• So closed die forging is also referred to as net shape or
near net shape process.
Advantages and disadvantages of open and closed
forging
Classification based on forging equipment
• The principle of operation is based on force that is supplied by a falling weight of
ram provided by a forging hammer/press.
• Deformation of work piece is due to the application of the kinetic energy of the
ram.
• Types of hammers/press:
1. Mechanical board hammer
2. Steam hammer (Power hammer)
3. Hydraulic press
Classification based on forging equipment
Mechanical board hammer
• It is a stroke restricted machine.
• Repeatedly the board (weight) is raised
by rolls and is dropped on the die.
• Rating is in terms of weight of the ram
and energy delivered.
Classification based on forging equipment
Steam hammer
• It uses steam in a piston and
cylinder arrangement.
• It has greater forging capacity.
• It can produce forgings ranging
from a few kgs to several tonnes.
• Preferred in closed die forging
Classification based on forging equipment
Hydraulic press
• The machine has more of
squeezing action than hammering
action.
• Hence dies can be smaller and
have longer life than with a
hammer.
Forging operations
• Forging operations include:
1. Edging
2. Upsetting
3. Fullering
4. Drawing
5. Swagging
6. Piercing
7. Punching
8. Bending
Forging applications
• The wide range of alloys and sizes, combined with excellent mechanical and physical
properties has made forgings the design choice for nearly all product areas.
13. Mechanical power transmission equipment,
• Common applications of forgings include: incl. bearings
1. Aerospace
2. Aircraft Engines 14. Off-highway, equipment (construction, mining
and materials handling
3. Airframe and auxiliary equipment
4. Guided missiles and space vehicles 15. Oil field machinery and equipment
5. Automotive - Passenger cars Trucks, 16. Pipeline fittings
busses and trailers, Motorcycles and
bicycles 17. Plumbing fixtures, valves and fittings
6. Bearings, ball and roller
7. Electric power generation/transmission 18. Pumps and compressors
8. Industrial and commercial machinery and 19. Railroad equipment and spikes
equipment
9. Hand Tools 20. Rolling, drawing and extruding equipment and
10. Industrial tools tools for nonferrous metals
11. Internal combustion engines 21. Ship and boat building and repairs
12. Metalworking and special industry
machinery 22. Special industry machinery
23. Steam Engines and turbines
24. Steel works, rolling and finishing mill
Defects and remedies in forging processes
Tools and accessories used in forging processes
• There are a number of tools used in hand forging operation:
• Anvil
• Tongs
• Set hammers
• Punches
• Swage block
• Swages
• Fullers
• Chisels
• Flatters