Press forging is a metal shaping process where a metal is placed between two dies and gradually shaped by applying mechanical or hydraulic pressure. This process is distinct from impact forging, which uses a sudden impact force. Press forging can be performed as either hot or cold forging, and it is particularly suitable for high-volume production of forgings.
Process Details: Press forging is typically carried out on a forge press, which uses a vertical ram to apply controlled pressure to a die holding a workpiece. This method contrasts with drop forging, which employs a series of blows to deform the material. The slow movement of the ram in press forging allows for deeper and more uniform plastic deformation of the workpiece.
Types of Dies: There are two main types of dies used in press forging: open and closed. Open die forging does not completely enclose the workpiece, allowing some freedom of movement for the metal. In contrast, closed die forging, also known as impression die forging, completely surrounds the workpiece, ensuring that the metal fills the die cavities precisely.
Types of Forging Presses: Forging presses can be categorized by the type of force they apply and their frame design. The most basic type is the mechanical press, which uses a flywheel to store energy and a crank mechanism to move the ram. Other types include hydraulic presses, which use hydraulic motion to move the ram, and screw presses, which use a screw mechanism. These presses can apply up to 12,000 tons of pressure and are capable of forging alloys with moderate ductility that might shatter under the impact of a hammer.
Advantages of Press Forging: Press forging offers several advantages over impact or drop forging. It completely deforms the workpiece, allows for controlled compression rates, and is more economical for high-volume productions. Additionally, it can create any size and shape, requires less draft, and produces less scrap.
Industrial Applications: Press forging is used in various industrial applications, including the making of coins, silver articles, and automatic forgings. Techniques such as coining and hubbing, which use closed dies, are common methods within press forging. Coining, for example, is used to make coins and involves enclosing the metal in a die and applying high pressure to achieve fine details.
In summary, press forging is a versatile and efficient method for shaping metals, particularly suited for high-volume production and capable of producing detailed and complex shapes with controlled precision.
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