Metal Forging - Casting-Forging-Machining

What Is Metal Forging?

Metal Forging is the process of shaping a piece of metal using continuous pressure, often used to tool steel or iron. The extreme pressure may require rolling, pressing, or hammering the workpiece to shape it into the desired part. Common examples of forged parts include rolled steel bars and beams.

Press forging is one of the most used processes. Instead of hammering or rolling the material, a press is used to shape the part. To compress the material, the press generates significant force. Some presses may use 50,000 tons of pressure.

After forging the part, the new shape has a denser structure, making it stronger and more resilient. Many types of forging exist. The press forging methods are often categorized based on the temperature at which the parts are forged. The main categories include cold, warm, and hot forging.

Metal Forging Process

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Types of Metal Forging

Cold Forging

Cold forging is an efficient and economically effective method of forming metal to manufacture large volumes of parts at low costs. The forging method is different depending on the temperature: cold or hot. It’s accomplished by machines with hammers, or by a press for shaping, pressing, and rolling steels.

This technique is comparatively less costly than hot forging as the end products require very little finishing work. Although cold forging is called cold, it happens at or close to room temperature.

The size of the machines to accomplish cold forging varies with the material hardness and the weight of the final component to be processed.

Free Forging

Free forging, also known as open die forging or smith forging. The forming characteristic of free forging is that the blank is completed by gradual local deformation on the flat anvil or between the tools. Since the tool is partly in contact with the billet, the required grid work is much smaller than that of the die forging bar for producing forgings of the same size, so free forging is suitable for forging large forgings.

Hot Forging

Hot forging requires the metal to be heated above its recrystallization temperature. This allows for the flow stress and energy required to form the metal to lower, effectively increasing the rate of production (or strain rate). Hot forging aids in making the metal easier to shape as well as less likely to fracture.

Iron, along with its alloys, are almost always hot forged for two main reasons: #1) If work hardening progresses, hard materials (such as steel and iron) will become more difficult to work with, and #2) It is a more economical option to hot forge metals such as steel and then follow with heat treatment processes as metals such as steel can be strengthened through other processes (and not necessarily just cold working processes).

Warm Forging

Warm forging is performed with the workpiece heated to a range that is generally above the work hardening temperature and below the temperature at which scale forms. The process fills the niche between the closer tolerance, but sometimes expensive cold forging process and the somewhat lower precision hot forging process. It is being used to produce close tolerance components in steel alloys that were not feasible or impossible by cold forging. It is also being used to produce components very close to final shape that were formerly made by hot forging with generous finishing allowances. Shafts, gears and automotive front wheel drive tulips are currently being warm forged.

Forging Methods: Custom Service Tailored to Our Customer Needs

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Open vs. Closed Die Forging

Open die forging shapes material between flat dies to create larger parts, while closed die forging uses closed dies with pre-cut shapes to create smaller, intricate parts, providing precision and control.

Our open die forging services are often used for: Large shafts and bars, Cylinders and discs, Ring parts

Closed die forgings are often used for: Precision tool and die components, High-strength fasteners, Valve and fitting components.

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Cold Forging vs. Hot Forging

Cold forging is performed at or near room temperature, while hot forging involves high temperatures above the metal’s recrystallization point.

Cold forging is commonly used for: parts with complex shapes, precision forging of large parts, austenitic stainless steel parts

Hot forging is commonly used for: small and medium-sized parts, bearings and gears, medical devices and implants

Forging Applications

Aerospace

Automotive

Marine

Railway

Heavy Truck

Agriculture

Oil & Mining

Medical

Forging Advantages and Alternatives

Forging

Metal Casting

CNC Machining

*Strength and Durability:

Forged parts tend to be stronger and more durable due to the alignment of the metal’s internal grain structure, which enhances its mechanical properties.

*Economic Benefits for High-Volume Production:

While initial tooling costs can be high, once the tooling is in place, forging becomes cost-effective for mass production due to its efficiency and speed.

*Complex Shapes:

Ideal for producing complex shapes that may be challenging or costly through other manufacturing processes.

*Cost-effective for low-volume production:

Low to medium-volume production is often cost-effective compared to processes such as forging. Tooling costs are relatively low, and multiple parts can be produced in a single pour.

*Precision and Tight Tolerances:

Machining is highly accurate and can achieve tight tolerances, making it suitable for applications where precision is critical.

*Customization and Prototyping:

Machining is ideal for creating custom and prototype parts. This allows for quick adjustments and modifications during production.

*Surface Finish:

Machining can achieve a high-quality surface finish, which is important in applications where aesthetics or smooth surfaces are important.

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