Forging Processes

By
Satya Amarnadh Parimi
 FORGING

Forging - defined as metal working process by

which metals and alloys are plastically
deformed to the desired shapes by the
application of compressive forces.
FORGEABILITY:
The ease with which forging is done is called
forgeability. The forgeability of a material can also
be defined as the capacity of a material to undergo
deformation under compression without rupture.
FORGABLE MATERIALS
1. Aluminium alloys
3. Copper alloys.
5. Martensitic stainless steels
7. Nickel alloys
9. Columbium alloys
11. Molybdenum alloys
2. Magnesium alloys
4. Carbon and low alloy steels
6. Austenitic stainless steels
8. Titanium alloys
10. Tantalum alloys
12. Tungsten alloys
FORGING TEMPERATURES
 The temperature to start the forging for soft,
 low carbon steels is 1,250 to 1,300°C, the temperature to finish
forging is 800 to 840°C.
 The corresponding temperatures for high carbon and alloy steels
which are hard in nature are 1100 to l140°C and 830 to 870°C.
 Wrought iron is best forged at a temperature little below 1,290°C.
 Non ferrous alloys like bronze and brass are heated to about 600 to
930°C.
 the aluminium and magnesium alloys to about 340 to 500°C.
FORGING TOOLS
These are also called blacksmith’s tools, for a blacksmith is one
who works on the forging of metals in their hot state.
1. Tongs 2. Flatter
3. Swage 4. Fuller
5. Punch 6. Rivet header
7. Hot chisel 8. Hammers
9. Anvil 10. Swage block
11. Drift 12. Set-hammer
14. Brass scale 15. Brass
16. Black smith’s gauge 17. Heading tool
FORGING TOOLS
FORGING TOOLS
FORGING TOOLS
Forging Operations
The hand forging operations are
1. Upsetting 2. Bending
3. Drawing down 4. Cutting
5. Setting down 6. Punching
7. Flattening 8. Fullering
9. Forge Welding 10. Swaging
Forging Operations
Forging TOOLS
Forging Operations
Upsetting is also known as jumping operation which is carried out
to increase the thickness (or diameter) of a bar and to reduce its
length. Generally, the increase in thickness is only local, for
example, when forming a bolt head.
Bending is a very commonly used forging operation in forging
shop to give a turn to a metal rod or plate. It is accompanied by
spreading of the metal in the inside of the bend and narrowing at
outside.
Punching is a main forging operation used for producing hole in
metal plate by using a tool known as punch.
forge welding: It is a process of joining two metal pieces to
increase the length by pressing or hammering them when they are
at forging temperature. It is performed in forging shop and hence
sometimes it is called as forge welding.
 Drop forging
Drop forging is a metal shaping process, the
metal to be formed is first heated then shaped
by forcing it into the contours of a die, this
force can be in excess of 2000 tons. The drop
forging process can be performed with the
material at various temperatures.
There are two types of drop forging, open die
and closed die.
 Open Die Forging

• Open die forging is performed between flat

dies with no precut profiles in the dies.
• Larger parts over 200,000 lbs. and 80 feet
in length can be hammered or pressed into
shape this way.
 Open Die Forging
• It is used
- Number of components to be forged is
too small
- Size of the component is too large

Upper die

Billet

Lower die
Starting stock.
Preliminary upsetting.
 Progressive upsetting/
forging to disc dimension
 Impression Die Forging

• Impression die forging presses metal

between two dies (called tooling) that
contain a precut profile of the desired
part.
• It produces closed dimensional tolerances
• Parts from a few ounces to 60,000 lbs. can be
made using this process.
• Some of the smaller parts are actually forged
cold.
 Impression Die Forging Process Operations
• In impression die forging, two dies are
brought together and the workpiece undergoes
plastic deformation until its enlarged sides touch
the side walls of the die. Then, a small amount of
material begins to flow outside the die impression
forming flash that is gradually thinned.
• The flash cools rapidly and presents
increased resistance to deformation and helps
build up pressure inside the bulk of the
workpiece that aids material flow into unfilled
impressions.
Flash
 Forging defects
• Incomplete forging penetration (Dentritic structure will not
be broken at the interior surface)
• Surface crack
• High sulphur concentration in the furnace atmosphere can
produce HOT SHORTNESS in Steel & Nickel
• Crack at Flash
• Cold shut
• Loose Scale or lubricant may accumulate in deep recess of
the die
• Incomplete descaling of workpiece
• Internal cracks can develop during upsetting
• Laps (Metal Fold)
• Mismatch