Forging is one of the forming processes.

This is a process in which metal deforms plastically to another requires shape and size with the
help of a hand or Machine forging with a certain temperature.

Forging is done by two processes:

1. Hand forging
2. Machine forging

Hand Forging:
The workpiece is heated in the furnace after heating Keep the heated workpiece (with the
support of blacksmith tongs) onto the anvil and take the hammer are a strike on it, make the
required shape and size.

Machine Forging:
In this process, the operation is performed by the machine but we (Human) regulate the
machines.

Types of Forging:
The types of forging are:

1. Open Dies Hammer or Smith Forging

2. Impression Die Drop or Closed Die forging
3. Press forging
4. Upset forging
There are also two major types of forging, those are:

1. Hot forging
2. Cold forging

Open Dies Hammer or Smith Forging:

In the early days, we use this type of forging process. This is a very conventional type of
process.

In this process what we do once we heat the workpiece to the required temperature then we put
the workpiece on the anvil by the use of tongs. And now we strike on it with the use of hammer
for the required shape and size and you might study in the diploma or B-tech lab of forging.

The length of the workpiece decrease and the crosssection area of the workpiece increases. This
process does not require any external forging machine. Done by a human.

This is a very simple type of process.

Impression Die Drop or Closed Die:
It gives a more accurate size. In this, we make a complex shape like a crank, connecting rod,
wrench, etc.

To perform the operation we must have two dies (Upper and lower) lower is fixed and the upper
is moveable. In this operation, the workpiece is under the die to perform the operation as you can
think from the name.

There might be needed more than 2 operations to perform this process. You can see the diagram
as mentioned.

Open Die Forging VS Closed Die Forging

Open die forging operation is like the workpiece is forged between two open dies that mean there
are two die parallel to each other and compressing the workpiece.

Here workpiece material comes out while the operation is carried.

Whereas, the closed die forging is like a complete specified shape in which there are two dies
compressing the workpiece each other to get the desired shape.

Here the workpiece does not come out of the system.

Press forging:
The press forging is a little faster than the other two operations because in this we provide
continuous squeezing action.

This is much faster than a closed die because here only one squeeze is needed.

The final object we get from this process has good smooth, close tolerance and there is no such
problem of alignment of die in this operation.

The operation forms only in a single squeeze.

Upset forging:
I am trying to understand you by a simple example. Have you seen a cylinder head? Yes, you
might. In that what we do is first, heat the only parts you want to change the shape.

Like take a rod and heat it the above parts and after heating just make the required shape and size
that comes in upset forging process.

Cold Forging:
This is a forging type process in which operation is performed at room temperature. In cold
forging, there is no use of a furnace to heat the workpiece or too cold the workpiece.
How Cold forging operation performs:
The machines have two dies and in between the die, we place the workpiece between them and
apply the load on it so as per the shape and size we want we apply the required forces on it.

The advantage of clod forging is this is less costly.

Hot Forging:
The hot forging is performed at extremely high temperatures (up to 1150 °C for steel, 360-520
°C for al-alloys, 700-800 °C for CU-alloys).
This temperature is necessary because when you perform the operation of hot forging, the strain
hardening problem comes while deforming the workpiece.

In order to avoid strain hardening problems, you must work between the temperature as
suggested.

The advantages of hot forging are one good surface finish can be obtained, and the second
improves mechanical properties.

What is the difference between cold forging and hot forging?

Cold Forging Hot Forging

Hot forging is not done at room temperature. For specific material

Cold forging is done at room temperature.
having a specific temperature limit.

Dimension can be controlled when the Dimension can not control when operation is carried out as
operation is carried out. compared to cold forging.

Material is more ductile. Material is less ductile.

Low surface finish. Good surface finish.

Let introduce some of the forging tools:

There are a number of tools used in hand forging operation:

 Anvil
 Tongs
 Set hammers
 Punches
 Swage block
 Swages
 Fullers
 Chisels
 Flatters

Anvil:
Here workpiece is to be kept and with the use of a hammer, we strike to the workpiece for
changing the shape and size.

It is made of Mild steel.

It works like the bed of the system in hand forging.

Tongs:
Tongs are used for holding the workpiece. When the workpiece is heated, tongs are used to hold
it.

Set hammers:
It is used for striking the workpiece.

Punches:
It is a tool and used for punching the workpiece.

Swage block:
It is used for getting different sizes of workpieces.

It contains multiple shapes and size holes in it and we can insert the workpiece into it and strike
it with the hammer to get shape and size as we want.

Chisels:
Chisels are used for cutting metals in hot forging operation.
Flatters:
Flatters are used for flattening the workpiece.

Flatters and fullers both are the same types of equipment used as a tool in forging.

Forging Defects:
The general forging defects are:

 Unfilled sections
 Cold shut
 Scale pits
 Die shift
 Flakes
 Improper grain flow
 Surface cracking
 Residual stresses
 Incomplete forging Penetration
Let me discuss these defects in brief.

Unfilled sections:
The unfilled section defects can be because of the improper design of Die or Improver heat
treatment of metals.

Imagine there are two dies: one is upper (Moveable) and the second is lower (fixed), In between
we place the heated metal to form another require shape but due to the above line listed reason
the defects can occur.

Cold shut:
Cold shut defects occur in the forging operation when unable to fill the workpiece at the corner
of the complete die.

Scale pits:
The scale fit defects cause low strength of the forging operation because in these defects the slag
or some dust particles are available in the die and we are not cleaned before the forging operation
so it sticks to the forged metal.
Die shift:
The unfilled section defects can be because of the improper design of Die or Improper
adjustment of Die. To overcome this defect, we must have a good design of the die.

Flakes:
The flakes defects can cause because of the fast cooled of the upper die which is unable to makes
proper forged operation.

Improper grain flow:

You must have to design a proper die to not to perform such defects.

Surface cracking:
The reason for the defect is the improper temperature provided. To overcome these defects you
must provide the required temperature for the working metals.

Residual stresses:
The reason for this defect is the fast cooling of improper parts. To overcome these defects you
must do proper and slow cooling of forged parts.

Incomplete forging Penetration:

While hammering on the workpiece by hand due to improper hammering this defect generates.
To overcome, you must do proper hammering on it.

You can check this article from science direct to know more about the prevention of forging
defects.

Forging Advantages:
The main advantages of forging are:

 The process gives higher strength products as compared to casting.

 A good number of shapes can be made through this process.
 The process does not require a skilled operator, anyone can do it. The only thing is to have to teach
once.
 Low-cost operation.
 The Mechanical Properties like (Hardness, Strength and other) having good.
 It refines the structure of the metal.
 The forged parts can be easily welded.
 A reasonable degree of accuracy can be obtained in this process.

Forging Disadvantages:
The main disadvantages of forging are:
 The secondary finishing process requires.
 The size might be limited because of the press size.
 The maintenance cost is high.
 The metals gots distorted if works below the required temperature.
 The initial cost is high. In advantage, I have mentioned operation cost is low.
 Some material can not be forged in the forging process.
 The close tolerance is might not achieve in this process or difficult to maintain.
 Rapid oxidization in forging of a metal surface at high-temperature results in scaling which wears the
dies.
 While performing Forging operation by Hand you must have good energy to strike on the workpiece
by the hammer.
 A huge safety requires because you are working near more than 2000 degrees centigrade.

Applications of Forging operation:

There are various applications of forging, and those are:

 This process gives higher fatigue strength so like camshaft, the crankshaft is made by the forging
operation.
 Cold forging is used for making Knife, Chisel, bolts and many more.
 Automobile Industry
 Hand tools and Hardware
 Industrial tools.

 Alloy Steel
 Aluminum
 Carbon Steel
 Nickel Based Alloys
 Stainless Steel
 Titanium
 Tool Steel

Alloy Steel
Typically forged by using hot forging processes, alloy steel is one of the most commonly
used forging materials. Stronger, tougher and offering more resistance to wear when
compared to carbon steel forgings, alloy steel are commonly alloyed with the following
materials to enhance its physical properties:
  Nickel, chromium, silicon, molybdenum, vanadium boron and manganese.

Some of the more popular alloy steels used

American Iron and Steel Institute (AISI)

Aluminum
Working with a large number of aluminum grades, ChinaSavvy is capable of producing
high quality aluminum forgings to rival some of the best metal forging companies
operating within the industry today.
Overall, aluminum alloys have a strong resistance to corrosion, while aluminum open
die forging, when compared to casting, offers superior internal integrity, maximum
impact strength as weel as an elimination of internal voids.

Carbon Steel
The ideal forging materials for high pressure and high temperature applications,
ChinaSavvy works with the following forging materials in this category:

Note: You can click on the table to view a larger image.

ChinaSavvy also works with ASTM A105 Carbon Steel (which is forged at temperatures
of between 1700°F (926°C) and 2200°F (1204°C), followed by normalizing or quenching
and tempering) and ASTM A350 LF2 (which is forged between 1652°F (900°C) and
2192 °F (1200°C) with soak times being kept to minimum in order to avoid heavy
scaling).

Nickel Based Alloys

Requiring special expertise to forge, the nickel based alloys used by ChinaSavvy
includes, but are not limited to:
A metal must be heated to a temperature at which it will possess high plastic properties
to carry out the forging process. The metal work piece is heated to a proper temperature so
that it gains required plastic properties before deformation, which are essential for
satisfactory forging. Excessive temperatures may result in the burning of the metal.
Insufficient temperatures will not introduce sufficient plasticity in the metal to shape it
properly by hammering etc. Moreover, under these conditions, the cold working defects
such as hardening and cracking may occur in the product.

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 temperature should be proper to get good results. Excessive temperature

may result in the burning of the metal, which destroys the cohesion of the metal.
Insufficient temperature will not introduce sufficient plasticity in the metal. The forging
operation in metal is if finished at a lower temperature, it may lead to cold hardening and
cracks may develop in it. However, excessive heating of the forgeable part may result in
oxidization and hence material is wasted. The temperature of heating steel for hand forging
can be estimated by the color of heat and which color of the light emitted by the heated
steel. For accurate determinations of forging temperatures of the heated part, the optical
pyrometers are generally used.