Forging is a metalworking process that improves the mechanical properties of metals.
It does this by applying compressive forces like pressing, hammering, or rolling.
This method is efficient and cost-effective.
It produces components with high ductility and better resistance to impact and fatigue.
Forging can be applied to various metals, including stainless steel, titanium, carbon steel, and metal alloys.
What is the Process of Forging? (7 Key Steps Explained)
1. Metals Used for Forging
Carbon Steel: This is a common choice for forging.
Its hardness is determined by its carbon content.
Alloying elements like chromium, titanium, nickel, and others can be added.
Forged carbon steel is economical for applications that do not require high temperatures or extreme strength.
2. Forging Press
A forging press operates by using a vertical ram to apply controlled pressure to a die holding a workpiece.
This process differs from drop forging, which uses a series of blows.
It uses slow pressure to achieve uniform plastic deformation in the workpiece.
The dies can be either open, where the workpiece is not completely enclosed, or closed (impression die forging), where the die fully surrounds the workpiece.
The press can apply up to 12,000 tons of pressure using either hydraulic or mechanical force.
3. The Forging Process
Flash Formation: Heat-treated steel bars are placed between upper and lower dies and heated from billets.
They are then pressed into the desired shape.
Trimming: After the formation of forging blanks with flash, the excess material (flash) is removed by pressing the blanks under trimming dies to achieve a complete forging blank.
4. Press Forging – Metallurgical Processes
Press forging involves shaping metal between two dies by applying mechanical or hydraulic pressure.
This process is typically performed on a forge press, which applies gradual pressure to the dies.
The shaping is usually accomplished in a single stroke for each die station.
The key distinction from impact forging is the gradual application of pressure rather than a sudden impact.
5. Steps to the Forging Process
Designing & Creating Dies: Dies are designed based on the product specifications.
This step is crucial for achieving the desired shape and quality of the forged parts.
Cutting and Heating the Billet: Steel billets are cut to the required length and heated in a medium-frequency furnace before undergoing the forging process.
This detailed explanation covers the fundamental aspects of the forging process.
It highlights its efficiency and the versatility it offers in terms of the metals and applications it can serve.
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