Forging

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File:Boat nail production.ogv Forging is a manufacturing process involving the shaping of metal using localized compressive forces. The blows are delivered with a hammer (often a power hammer) or a die. Forging is often classified according to the temperature at which it is performed: cold forging (a type of cold working), warm forging, or hot forging (a type of hot working). For the latter two, the metal is heated, usually in a forge.

Overview

Forging can produce a piece that is stronger than an equivalent cast or machined part. As the metal is shaped during the forging process, its internal grain deforms to follow the general shape of the part. As a result, the grain is continuous throughout the part, giving rise to a piece with improved strength characteristics. This is particularly important for high-stress applications like aerospace, automotive components, and industrial machinery.

Types of Forging

Closed Die Forging

In closed die forging, the metal is pressed between two molds (called dies) that contain a precut profile of the desired part. This process can produce parts with tight tolerances and is often used for large production runs. Components made by this method include crankshafts, gears, and other critical parts for automotive and aerospace industries.

Open Die Forging

Open die forging, also known as smith forging, involves the deformation of a workpiece between two dies that do not enclose the workpiece, allowing the metal to flow except where contacted by the dies. The process is used for large products or when the quantity does not justify the expense of closed dies.

Seamless Rolled Ring Forging

Seamless rolled ring forging is used to create rings of various sizes for applications in industries such as aerospace, energy, and defense. The process involves piercing a hole in a round piece of metal to create a donut shape, and then rolling and squeezing the donut to increase its diameter and reduce its thickness.

Materials

A wide range of metals can be forged. Commonly forged metals include carbon steel, alloy steel, stainless steel, aluminum, titanium, and copper. The choice of material depends on the desired attributes of the final part, such as strength, weight, or resistance to wear and corrosion.

Advantages and Disadvantages

Advantages

- Improved mechanical properties: The forging process aligns the grain structure and improves the toughness and strength of the metal. - Reduced material waste: Forging can be more material-efficient than machining from solid material. - Variety of shapes: Forging can produce a wide range of shapes and sizes, from small components to large industrial parts.

Disadvantages

- Higher cost for low volume: For high production runs, the cost of forging dies can be spread over many parts, but for small quantities, forging can be expensive. - Limitations on complexity: While forging can produce complex shapes, the most intricate designs may still require machining or other finishing processes.

Applications

Forging is used in a variety of industries where reliability and strength are paramount. The automotive industry relies on forging for components such as crankshafts, connecting rods, and gears. The aerospace industry uses forged parts for critical applications like landing gear, engine mounts, and structural components. In the energy sector, forged components are used in oil and gas drilling and extraction equipment, as well as in power generation turbines.

Conclusion

Forging is a critical manufacturing process that offers unparalleled strength and reliability for metal parts. Its applications span across critical sectors, underscoring its importance in modern manufacturing and engineering. Despite its limitations, the advantages of forging—such as improved material properties and the ability to produce a wide range of shapes—make it an indispensable technique in the production of durable and critical components.

Forging Resources
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