What is Forging?

https://www.youtube.com/watch?v=dFnN1YtomNc
https://www.youtube.com/watch?v=EKsiT_-swBM
https://www.youtube.com/watch?v=P0pNPuw5rSM
https://www.youtube.com/watch?v=-CT3230Vszw
https://www.youtube.com/watch?v=IxQdRZnOSrQ
https://www.youtube.com/watch?v=s6KwKcsoJSw
Different Types of Forging and Their Advantages
The pounding action of forging deforms and shapes the metal, which results in unbroken
grain flow. This causes the metal to retain its strength. Ancillary effects of this unique grain
flow include the elimination of defects, inclusions, and porosity in the product. Another
advantage of forging is the relatively low costs associated with moderate and long production
runs. Once the forging tools have been created, products can be manufactured at relatively
high speeds with minimal downtime.

Hot Forging
There are two main types of forging -- hot and cold. Hot forging requires the metal to be
heated above its recrystallization temperature. This can mean heating metals up to 2,300
degrees Fahrenheit. The main benefit of hot forging is the decrease in energy required to form
the metal properly. This is because excessive heat decreases yield strength and improves
ductility. Hot forged products also benefit from the elimination of chemical inconsistencies.

Need a hot forging company? Thomas' Supplier Discovery has a vetted list of Hot Forging
Companies in the U.S. and Canada.

Cold Forging
Cold forging typically refers to forging a metal at room temperature, though any temperature
below recrystallization is possible. Many metals, such as steel high in carbon, are simply too
strong for cold forging. Despite this hindrance, cold forging does edge out its warmer
equivalent when it comes to standards of dimensional control, product uniformity, surface
finish, and contamination. Cold forging encompasses numerous forging techniques, including
bending, extruding, cold drawing and cold heading. However, this increased versatility comes
at a cost, because cold forging requires more powerful equipment and may call for the use of
intermediate anneals.

Need a cold forging company? Thomas' Supplier Discovery has a vetted list of Cold Forging
Companies in the U.S. and Canada.

For more detailed info on either of these processes please read our Full Guide to Hot Forging
and Cold Forging.

Forging Process Categories

Beyond basic hot and cold forging, many specific processes exist. This broad range of
processes can be grouped into three primary umbrella groups:

 Draw forming decreases the width of the product and increases length.
 Upset forging increases the width of the products and decreases length.
 Compression forming provides forging flow in multiple or customized directions.

These three categories entail many different specific types of forging:

Open Die Forging Process

When flat dies that have no precut profiles engage in forging, the process is called open die
forging (or smith forging). The open design allows the metal to flow everywhere except
where it touches the die. To achieve maximum results, correct movement of the workpiece,
which should be over 200,000 lbs. in weight and 80 feet long, is essential. It is useful for
short-run art smithing or for shaping ingots prior to secondary shaping measures.

Closed Die Forging Process

Closed die forging, sometimes called impression die forging, employs the use of molds.
These molds are attached to an anvil while a hammer forces molten metal to flow into the
cavities of the die. Multiple strikes and/or die cavities are often used when forging complex
geometries. High initial tooling costs make closed die forging expensive for short-run
operations, but the forging process becomes cost-effective as parts produced increases.
Closed die forging also provides exceptional strength over alternative methods. Common
applications of closed die forging include the production of automobile components and
hardware tools.

Press Forging
In press forging, the main forming factor is compression. The metal sits on a stationary die
while a compression die applies continuous pressure, achieving the desired shape. The
metal's contact time with the dies is considerably longer than other types of forging, but the
forging process benefits from being able to simultaneously deform the entire product, as
opposed to a localized section. Another benefit of press forging is the ability of the
manufacturer to monitor and control the specific compression rate. Applications of press
forging are numerous, as there are relatively no limits to the size of product that can be
created. Press forging can be hot or cold forged.

Roll Forging Process

Roll forging is the process of increasing rods or wires in length. The manufacturer places
heated metal bars between two cylindrical rolls, which rotate and apply progressive pressure
to shape the metal. Benefits of roll forging include the elimination of flashing and a superior
grain structure.

Forging and its types

 Forging is the operation where the metal is heated and then a force is applied to
manipulates the metals in such a way that the required final shape is obtained.
Forging is generally a hot working process through cold forging is used
sometimes.
Type of forging
1. smith forging
2. drop forging
3. press forging
4. machine forging
1: Smith forging
This is the traditional forging operation done openly or in-openly dies by the
village black smith or modern shop floor by manual hammering or by the power
hammer. The process involves heating the stock in the black smith hearth and
then beating it over the anvil. To get the desire shape the operator has to
manipulate the component in between the blows.
The types of operation available are fullering, flattering, bending , upsetting and
swaging.
2: Drop forging
Basic definition:
This is the operation done in closed impression dies by means drop hammer
here the force for shaping the component is applied in a series of blows.

Drop forging utilizes a closed impression die to obtain the desire shape of the
component , the shaping is done by the repeated hammering given to the
material in the die cavity. The equipment use for delivering for blows are called
drop hammers. The drop forging die consists of two halves. The lower halve of
the die is fixed to the anvil of the machine , while the upper halve is fixed to
ram. The heated stock is kept in the lower die, while the ram delivers 4-5 blows
on the metal spreads and completely fills in the die cavity. When the two die of
halves closed the complete is formed. The typical products obtained in drop
forging are cranks, crank shaft, connecting rods, wrench, crane hooks etc. The
types of operations are fullering, edging, bending, blocking , finishing and
trimming etc.
3: Press forging
Similar to the drop forging , the press forging is also done in closed impression
dies with the expectation that the force is continuous squeezing type applied by
the hydraulic press. Press forging dies are similar to drop forging dies as also
the process in press forging, the metal is shaped not by means of a series of
blows as in drop forging , but by means of a single continuous squeezing action.
This squeezing is obtained by means of hydraulic presses. Because of the
continuous action of by hydraulic presses, the material gets uniformly deform
through out its entire depth ,the press forging dies with the various impression ,
such as fuller, bender and finisher impression properly arranged .
4: Machine forging:
Unlike the press or drop forging where the material is drawn out , in machine
forging the material is only upset to get the desire shape. As it involves the
upsetting operation some time it is simply called as upset forging. Originally
this was develop for making bolts head in a continuous fashion, but now there
are fairly large number of diverse.
Uses of this process:
Because of the beneficial grain flow obtain from upsetting. It is used for making
gears, blanks, shafts, excels, and similar parts. Upsetting machine called up
setter are generally horizontal acting. The die set consists of die and
corresponding punch or a heading tool. The die consists of two parts, one called
the stationary gripper die which is fixed to the machine frame and the other
movable gripper die which moves along with the die slide of the up setter. The
stock is held then between these two gripper dies.
The upset forging cycle start with the, movable die sliding against the stationary
die to grip the stock. The two dies when in closed position from the necessary
die cavity then the heading tool advance against the stock and upset it to
completely filled to the die cavity.
Having completed the upsetting the heading tool moves back to its back
position. Then the movable gripper die releases the stock by sliding backward.
Similar to drop forging it is not possible to get the final shape in a single pass in
machine forging also. Therefore the operation is carried out in number of stages.
The die cavities is required for the various operations are all arrange vertically
on the gripper dies. The stock is the move from stage one to another in proper
sequence till the final forging is ready. A heading tool each for every upsetting
stage is arranged on the heading slide of the upsetting machine. A typical
upsetting die and heading tool is shown:
 The 3 Essential Forging
Temperatures
1. Home
2. Steel
3. The 3 Essential Forging Temperatures
The forging industry has a broad range of manufacturing processes,
making many different types of products. From aerospace fasteners
and the automotive industry to hardware and tools, forged products
can be found just about everywhere you look. The Forging Industry
Association provides a great brief overview video of all the different
types of forging processes. Aluminum, copper, steel and titanium
are the most popular metals that are used in the forging process.
While there are a number of different ways to forge metal, the
process essentially remains the same. It requires heating a piece of
metal and then deforming that metal into a particular shape. For
some forged parts, temperature control is critical in achieving the
desired metallurgical and structural properties of the newly forged
part. Here are three essential temperatures that need to be
measured in the forging process.

1. Billet Temperature
There are really two types of billet temperature, one that is done
inside a billet furnace (done for batch heating), the other is done
prior to die entry to make sure that the part is hot enough before it
enters the die.

1a. In-Furnace Measurement

In a forging plant, aluminum,

brass, or steel billets are heated in furnaces before they are loaded
into the forging die to be formed. Billets may be large or small and
the billet furnace may be gas-fired or induction-heated. In some
cases only the end of a product, such as the end of a rod or tube, is
heated and formed. In other cases, the entire billet is heated. The
efficiency of the heating process and the consistency of the formed
product rely on a well-controlled billet preheat temperature.
When measuring inside a gas-fired furnace wavelength selection is
critical to sensor performance. Infrared temperature sensors need
to be filtered at wavelengths that view through flames and
combustion byproducts without interference in order to make an
accurate reading. Ratio pyrometers are typically recommended as
they automatically compensate for emissivity variation and can
tolerate moderate surface scale. If you have a wide tolerance for
temperature error, single-wavelength pyrometers filtered at a short-
wavelength can be used to minimize sensitivity to emissivity
variation and scale.

1b. Die Entry Measurement

An infrared thermometer is an essential tool when heating a billet
with an induction heater or as a final temperature verification
before the billet is inserted into the die. Temperature feedback is
necessary to assure consistent billet temperature, to avoid die
damage, and to assure quality production of the formed parts.
The infrared thermometer is most effective when used to measure
the temperature during the heating cycle rather than simply as a
verification after the billet has already left the heater. Sometimes
the sensor may be mounted to view into the induction furnace
between the windings of the coil, or through the furnace exit port. In
other cases it may be desirable to insert a fiber optic probe
(nonconductive light pipe) through the induction coil side wall.

2. Die Temperature

The forging die temperature has

a significant impact on the consistency of the forged part. A die that
is too hot or too cold will wear prematurely, will require excess
lubricant to assure proper forming or to prevent sticking, and will
affect the quality of the formed part. If the die is too hot, then
surface blemishes melting may result. If the die is too cold, then
surface cracks may occur.
Measurement of the die temperature is complicated by an
intermittent target, intermittent flames, lubricant sprays, and the
insertion and removal of the billet and forged part. Certain
Williamson infrared thermometers are supplied with a patented
signal conditioning technique that allows the sensor to recognize
valid measurement conditions. Using this unique feature, the
pyrometer measures only the die temperature. Interference from
flames, lubricants, billets, and forged parts is completely
eliminated, and only the die temperature is measured. This
innovative capability provides for a simple and easy die temperature
measurement.

3. In Process Temperature

An infrared thermometer may be

used to monitor process temperatures during the forming process
for those forging procedures where the metal part is exposed to
view during as it is formed. While the formed part can not be viewed
during the closed die forming process, it may be viewed in an open
die process, including hammer-formed and ring-formed parts.
The temperature of the part being formed is critical for the forging
process. Once the part is removed from the preheat furnace it
gradually loses heat. If the part were to become too cool, then it
will crack as it is formed, and the deformation tooling will wear
prematurely. In addition, the part temperature may be used directly
for process feedback, as a well-heated part may undergo a greater
deformation with each strike than one that is approaching the lower
temperature limit of deformation. Therefore, the impact may be
adjusted to optimize each strike according to the temperature of
the part to be deformed.
By accurately controlling for temperature at these three different
parts of the forging process, you can improve product quality,
reduce scrap, and improve process efficiency. To learn more about
which pyrometer technology is most appropriate for your
application, download our free wavelength selection guide.

Are you looking to know more about Forging?

Today we will study the definition, process,
types, operation, defects, advantages,
disadvantages, and applications of forging.

Also at the end of the article, I will give you the

link to download the PDF version of this article.
Let’s begin with the definition of forging:

Forging Definition:
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 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) regulates 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 than 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 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

operation 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 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 furnace to heat
the workpiece or too cold the workpiece.
How Cold forging operation
performs:
The machines having two dies and in between
die we place the workpiece between them and
apply the load on it so as per the shape and size
we want we apply required forces on it.

The advantage of clod forging is this is less

costly.

Hot Forging:
The hot forging is performed at extremely high
temperature like (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 problem, 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

Cold forging is done at room Hot forging is not done at room temperature. For specific
temperature. material having a specific temperature limit.

Dimension can be controlled when Dimension can not control when operation is carried out
the operation is carried out. as 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 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
workpiece.

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 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 this defects the
slag or some dust particles available in the die
and we 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 unable to
makes proper forged operation.

Improper grain flow:

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

Surface cracking:
The reason for the defect is 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 is used in the ship-building process.

 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.
 Forging operation maybe use in defense
equipment.
 Automobile Industry
 Hand tools and Hardware
 Machinery equipment.
 Industrial tools.

Why forging is required?

Forging is a manufacturing process in which
we obtain different shapes and sizes of a metal
by the operation of hot and cold forging.

Other manufacturing processes like casting

where liquid metals are poured into a mold and
the operation are carried but when we talk
about forging, the operation performs on
metals.

In simple words, the forging is required to

change the shape, size of the same workpiece
by heating or compressing.
A video of forging operation:

Conclusion:
So now I hope I clear all your doubts regarding
Forging.

Now I want to hear from you. If you like my

article do share with your friends and also on
your social handles. And also you can comment
down below your doubts, or whatever you
wanna tell me. I love to hear your opinion and
suggestions.

We also have dedicated Facebook community

for you guys, if you wish you can join our
community, here is the link of our Facebook
group. So, Cheers, and enjoy the rest of your
day.

Also, I wrote an article on parts, types, and

operations Lathe Machine and also parts,
types and operation of Shaper Machine you may
be interested to read that too.

 Wanna need more this type of article on the

Manufacturing Process? Here it is.

You may be interested to read these

articles:
Powder Forging:
As the name denotes Powder Forging, that
means here we use Powder Metals to get finish
product. In this process, a mixture of blended
powder poured into the die through the hopper,
and the pressing is done by using a preform.
Generally to get solid bonding we need to heat
the Preform.

This process is completed into three steps:

1.Perform is heated, so that binding can be

easily done.
2.Pre-Alloy powder (180–325 µm, source Open
Learn) put into the die and pressed by the
Preform. In this process, we get 80–85% solid
density.
3.After pressing done by preform, it again goes
for Mechanical Pressing, so that we can
increase the density up to 98–99.5%.
 Forging:
Forging is the process by which the metal can
be heated at a very high temperature. This
Forging process can be used to give a particular
shape to the metal. It usually works due to the
compressive force.

At first, the metal is heated at a very high

temperature. Then this metal is placed in a die.
After that, the compressive force is given to the
heated metal as the metal can get the shape of
the die by deformation with the help of the force
that is given by the hammer or the other piece
of the devices to the metal. Hence, the metal
takes its shape by deformation.
 Forging is a manufacturing process, which shapes a solid-phase metal workpiece by applying
compressive forces on it. According to the temperature at which it is performed, forging is
classified in “hot”, “warm” and “cold”. The machines used to squeeze and deform the material
into high strength parts can be divided in the following categories:
 Drop forging machines: forging hammers, screw presses, axial and incremental forging
 Pressure forging machines with translational motion: mechanical and hydraulic presses
 Pressure forging machines with rotational movements: longitudinal and radial rolling mills
 Combination of pressure machines with translational and rotational movements: orbital forging
and flospinning

Grain Structure of Forged Components

It is essential to note that the forging

manufacturing process is completely different from the casting one, where the molten material is
poured into a mold. Another significant difference to the other manufacturing methods as casting
and machining is that forging improves the mechanical properties of the material by refining its
grain structure, providing a good grain flow, and making it tougher and stronger.

The Cold Forging Manufacturing Process

The cold forging manufacturing process is performed at room temperature. The workpiece is
squeezed between two dies until it has assumed their shape. To deliver a finished, ready to fit
component, the technique includes rolling, drawing, pressing, spinning, extruding and heading.
Cold forging extrusion is one of the most common manufacturing techniques, widely used in the
production of automotive components.
Cold Forged Components
Advantages of Cold Forging
Manufacturers may prefer cold over hot forging process; since cold forged parts require very
little or no finishing work. Since all bars are annealed before being forged, there is no need for a
secondary heat treatment prior to machining. Another significant advantage is the material
savings achieved through near net shapes. The initial weight of the workpiece equals the final
weight of the cold forged component. Cold forged parts offer a good level of attainable
dimensional accuracy and excellent surface quality.
The economic advantages combined with high production rates and long die life are more than
enough to convince many manufacturers that cold forging is the best option for them.

Disadvantages of Cold Forging

Depending on the manufacturer’s requirements, some of the cold forging characteristics may turn
out disadvantages; e.g. only simple shapes in high volumes can be shaped. The achievable
deformation levels and shaping grade are much more limited compared to stamping. Therefore, if
the customer is searching for a specific customized component, cold forging won’t be the best
alternative.

A second more significant disadvantage is that cold forged metals are less ductile, which makes
them inappropriate for certain configurations. Also, because of the grain structure that gives the
material its strength, residual stress may occur.
It is important to mention that cold forging extrusion for example requires also a heat treatment to
eliminate possible cracks, creeks hardening or rafters.

As a consequence of the above statements, cold forging cannot be used on every steel grade,
particularly on those with low ductility or sensitivity to strain hardening. For instance, low alloy
steel with carbon content higher than 0,05% is not appropriate for cold forging.

The Hot Forging Manufacturing Process

The hot forging manufacturing process is performed at extreme high temperature (up to 1150
°C for steel, 360 to 520 °C for al-alloys, 700 to 800 °C for cu-alloys). This temperature is
necessary in order to avoid strain hardening of the metal during deformation. Stamping is the
most widespread hot forging manufacturing process, where the material is squeezed in a press,
between a tool and a die surface.
Hot Forged Components

Advantages of Hot Forging

 The high temperature during hot forging enables the highest possible level of material
deformation and the access to complex 3D geometries. Hot forged components possess
increased ductility which makes them desirable for many configurations. Also, as a technique hot
forging is more flexible than cold forging, since customized parts can be manufactured.

The excellent surface quality allows a wide range of finishing work as polishing, coating or
painting, tailored to customers’ specific need. Hot forging materials are available all over the
world which has a positive impact on their final price.

Disadvantages of Hot Forging

The properties of hot forged metals are obtained by subsequent heat treatment, where the
material has been quenched to 1000° C and then returned to 500 ° C. This requires additional
cost, which can be avoided if using cold forging (except in some cases as softening, annealing or
relaxation).

Less precise dimensional tolerance is another possible disadvantage of hot forged components
compared to the cold forged ones. The cooling process should be also performed under special
conditions; otherwise there is a risk of warping. Also, the grain structure of forged metals may
vary and there is always a possibility of reactions between the atmosphere and the workpiece.

The Cost Factor

The manufacturing process is a complex one that can be impacted by many factors as suppliers,
equipment, management styles, customers’ demand, etc. The more intense there are, the
greater the possibility for disruption in the process and changes in the final price. However, there
are 4 important factors that determine the final price of a forged component. These are:

1. The amount of the used material;

2. Forging costs as electricity, investments, tools, etc;
3. Post-forging heat treatments;
4. Additional operations as shot blasting or quality control tests.

Cost Efficiency in Cold Forging

Cost optimization in cold forging starts with the raw material. This one can be directly purchased,
if necessary, with an included annealing and a peeling, which makes the slugs ready for the
process. Since the number of raw materials for cold forging is limited, they are consequently
more expensive. To minimize manufacturing cost, cold heading wire is preferred for small pieces.

To obtain best cost efficiency the manufacturing process itself should be managed with an
excellent know-how of all involved tools and techniques. For example, large batches of cold
extruded components are manufactured on high speed mechanical presses, but complex parts
and small series rather on hydraulic presses.
An efficient lubrication system is of critical importance for the successful application of any cold
forged part. All workpieces should undergo a zinc-phosphate or polymer coating. Additional
lubrication with special forging oil is required on the multi-station presses. A good lubrication
system guarantees the high-quality of the final piece and eliminates additional costs for eventual
failures during the process.

Cost Efficiency in Hot Forging

The minimization of energy costs during hot forging is an ongoing concern of every
manufacturer. Those can be optimized when using an inductor and a billet with matching
diameters and installing a flexible multi-stage heating system.

The automatization of all involved forging presses is essential for the cost efficiency of the hot
forging manufacturing process, especially for industries that require high volume production runs
as the automotive one.

All applied tools should be optimized for the following innovative technologies:

Metallurgy: consolidated vacuum, powder metallurgy

Reloading
Heat treatment
Surface treatment: nitriding, carburizing and duplex treatment

The Main Difference Between Hot and Cold forging

The cold forging manufacturing process increases the strength of a metal through strain
hardening at a room temperature. On the contrary the hot forging manufacturing process keeps
materials from strain hardening at high temperature, which results in optimum yield strength, low
hardness and high ductility.

Finally, a manufacturer would choose one process over the other because of economic and not
quality reasons. The decision is based on the required functions of the desired component, the
industry and if it’s a mass production or a low volume of customized parts.

Setforge provides cold, warm and hot forging or combination of different processes to address
various customer demands, both performed in excellent conditions with state-of-the-art
machinery for perfect results. We work close with our customers to understand their specific
needs and find the best possible solution.
Hot Forging
The hot forging manufacturing process enables the manufacture of highly customised parts
with complex geometries due to the large amounts of plastic deformation and the consequent
increased ductility and decreased strength of the workpiece. The high temperature guarantees
excellent component integrity by distributing the material throughout the forged part and
eliminating inclusions. All metallic materials (ferrous and non-ferrous) can be forged in hot
condition and thus, hot forging process is the most common and well-known forging process.

The hot forging manufacturing process is performed at a higher temperature than the
recrystallization point of the work metal, thus avoiding strain hardening. This induces that a
full heat treatment is required on the parts after the forging, to optimize the metallurgical
structure and obtain the required mechanical properties.

To limit large dimensional tolerances, and the generation of scale and surface contamination
(such as decarburisation in steels, or H2 and O2 contamination in titanium alloys) a strict
control of atmosphere furnaces is required. Solid metallurgical knowledge to adjust the
forging and the heat treatment parameters and skills to design dies and preform tools for
optimized grain flow are of critical importance. Therefore the Research and Development
Engineering have tried to find different ways of forging (as cold and warm forging), aiming
at decreasing the heating temperature.

However, hot forging remains the only available and high-quality manufacturing process for
complex shapes, heavy-weight components and high-duty alloys. The forging division of
Farina Group - Setforge masters the whole spectrum of forging techniques and provides a
complete development of components, whether they are hot, warm, or cold forged. Setforge
combines experienced manpower and state-of-the-art machinery to meet the forging needs of
our diverse client base. Our strong, precise, reliable and cost efficient components are
successfully applied in a wide range of industries among others aerospace, agriculture,
energy, oil and gas. All Setforge process and main product lines are optimised with latest
manufacturing solutions and treatments for improved material characteristics and better
dimensional accuracy.

Our Expertise:

Global Manufacturing
Setforge La Clayette
Setforge Gauvin
Setforge Hot Formers
Setforge Estamfor
Setforge Electroforge
Barriol & Dallière Industries
Setforge L'Horme

Technical Characteristics
Material:
All ferrous and non-ferrous metal alloys
Some examples include:
structural steels
aluminum and magnesium wrought alloys
free-cutting steels
stainless steels
free-cutting steels
titanium alloys
molybdenum alloys
nickel/cobalt alloys

Equipment:
screw presses
hydraulic presses
drop, power drop or counterblow hammers
crank presses, ring rolling, cross rolling

Shaping and Tolerances:

design basis between ISO 10243 and ISO 10254
tolerance class forging grade F (IT 14)
tolerance class forging grade E (IT 16)
allowance of between 1,5 and 2 mm per surface
allowance of <1mm for near-net-shape surfaces
NF EN 10243 -1 with accuracy levels: quality F or E

Warm Forging

The warm forging manufacturing process occurs within the temperature range of 650 °C and
1000 °C, depending on the used material and the components type. This is usually above the
work hardening temperature of the workpiece and below the temperature at which scale
forms.
If the forging temperature is below the transformation point of 740-770 °C, the material
should undergo a preliminary heat treatment. This temperature range is used for parts with
medium complexity which don’t require heat treatment after forging. For parts with greater
complexity, the forging temperature is above the transformation point.

Although this temperature range is close to the one of hot forging, in terms of technology
warm forging is rather similar to cold forging.

The warm forging process is placed somewhere between the cold and hot forging techniques,
combining all their advantages as surface quality, precision, material usage and flexible
shapes but generally requires high engineering skills (tools design, cooling, lubrification) and
a dedicated forging press.

Warm forging is an important milestone of Setforge long-standing expertise in high-quality

manufacturing. Performed as a single production technique or as an extension to cold or/and
hot forging, our warm forging manufacturing process delivers mechanical components of
premium quality.

Our Expertise:

Global Manufacturing
Setforge Gauvin
Setforge Near Net

Technical Characteristics
Material:
carbon steels
low and high alloy steels

Equipment:
mechanical single and multi-stage presses
screw single and multi-stage presses

Shaping and Tolerances:

weight: 0.1 kg up to 5 kg
machining allowances: 0,5 to 1 mm
tolerance range: IT 10 to IT 13

Spectrum of Components:
CV joints
tulips
injector bodies
cylinder heads
shafts

Forging Presses
Besides hammers, presses are another compressive force instruments, used in the closed-die
forging manufacturing process. The material is “squeezed” between two dies and deformed by
the movement of the ram. The main deference between hammers and presses consists in the
way how the ram moves. Hammers deform the workpiece through repetitive strokes - from two to
several tens, according to the size of the hammer.

The activity of a closed-die forging press ram is typically characterised by:

- one stroke, in some cases 2, to fill the die
- a lower ram velocity:
2 to 50 mm/sec for a hydraulic press
200 to 300 mm/sec for a mechanical press
500 to 600 mm/sec for a screw press: as its velocity is higher, the screw press is an
intermediate tool between hammer and conventional presses.

Thanks to the fact that the applied force can be measured and recorded, press forging ensures
excellent traceability and repeatability of the production which is more difficult to achieve with
drop forging hammers.

The different types of forging presses have different applications:

 Hydraulic presses are used particularly for the manufacture of aluminium components, and
heavy steel or titanium components. The biggest press in the world for closed-die forging has a
nominal strength of 100 000 metric tons, in France - 65000 metric tons.
 Mechanical presses are used for large series production - usually 10 to 30 000 pieces per month.
They are suitable to any material, bur are preferably assigned the manufacture of automotive or
truck steel components.
 Screw presses are used for medium series production.

Setforge works with hydraulic, mechanical and screw presses. All of them deliver an excellent
degree of mechanical and orientation integrity.

Our Expertise:

Mechanical Presses at Setforge Gauvin

Global Manufacturing
Setforge Electroforge - screw presses
Setforge Estamfor - hammers, screw and mechanical presses
Setforge L'Horme - big hammers, mechanical press of 4500T
Setforge La Clayette - hammers, screw and hydraulic presses
Setforge Gauvin - mechanical presses
Setforge Extrusion - hydraulic presses
BDI - screw presses

Technical Characteristics
Material:
aluminum alloys
carbon steel
microalloyed steel
precipitation hardening steel (15-5PH, 17-4 PH)
stainless steel
Ni-base alloys
titanium alloys

Dimensions:
press hot forged components - from 0,1 to 40 kg
press warm forged components - from 0,2 to 5 kg
max. length - 550 mm

Equipment:
The choice of the forging press depends on the type of the desired product (morphology and material) and of
the rates of production:
Hydraulic press Mechanical press Screw press
Power range ~ 1 000T to 10 000T ~ 300T to 16 000T ~ 500T to 18 000T
Forging rate Slow High Average / high
Size of Small batches
Average and high
production Bigger batches on High quantities
quantities
batches small parts
Average, but adjustable Very high, but with an
Forging speed Fast, but without impact
and programable average impact
Adaptability to
Good Good Average
shape
Good (excellent for
Adaptability to Very good (all kind of Steel (acceptable for small
titanium alloys and small
Material material) aluminium parts)
parts)
Forging Hammers
Forging hammers are used in the drop forging to form the metal between two dies. The first half
of the die is attached to the anvil and the second part to the hammer. The material is placed in
the lower die and then hammered with the upper one until the hot metal flows in all directions,
filling the die cavity. Drop forging is the first industrial process which had been developed for
closed die forging, before the introduction of presses.

Hammers use impact strain to deform the material. The ram is thrusted into the workpiece with a
speed of more than 1/1,5 m/sec by sequence of several continuous blows on the same die; on
the contrary - forging presses need only 1 to 2 strokes. Hammers are characterised by the
energy produced in each blow (stroke), which is indicated in J, kJ and kg-m. A hammer of 250 kJ
(25 000 kgm) produces on each blow an energy equivalent of the drop of a mass of 25 metric
tons from 1 m height.

Hammers are classified in single effect (drop forging), double effect and counterblow hammers,
depending on the drive of the ram movement. These are very flexible and polyvalent tools, and
therefore dedicated mostly to small and medium series production. However, automatic
hammers have been developed to produce automotive parts in big series such as connecting
rods for automotive and trucks engines. Hammers are particularly suited to the forging of thin
components (such as con rods, airfoils) and heavy parts, made of steel, Ni-based alloys or
titanium.

Setforge owns excellent machinery and tooling equipped with best dies. We use single, double
effect and counterblow hammers, for all business fields, for steel, stainless steel, Ni-based alloys
and titanium components.

Our Expertise:

Counterblow Hammer Double Effect Hammer

Global Manufacturing
Setforge La Clayette
Setforge Estamfor
Setforge L'Horme

Technical Characteristics
Power Range:
big hammers - 1000/1400 kJ
automatic hammers - in the range of 50/560 kJ

Spectrum of Components:
automotive engine components
trucks engine components
thin components
heavy parts, made of steel, Ni-based alloys and titanium
Ferrous Alloys
Ferrous alloys are iron containing compounds, having a valance of +2 . The most common type
of ferrous alloy is steel with carbon contents of between 0 and 2 weight percentage. Other
alloying elements lead to the forming of carbides, which improve the material properties as
hardness, tensile strength and hardenability. Mild steel, stainless steel, cast iron and wrought
iron are other well-known ferrous metals, mainly praised for their tensile strength and durability.
Ferrous alloys are also the most recycled materials in the word.

Setforge provides all types of ferrous alloys. Our expertise includes a solid knowledge of the
metallurgy of the applied metals as forging temperature, HTcycle-heat treatment, following
forging process-cycle, etc. Our know-how in material deformation is of critical importance for the
final product. Setforge Engineering experts systematically use software simulation to ensure the
efficiency of the process when designing a new component.

Our Expertise:
Ferrous Railway Component

Global Manufacturing
Setforge Barriol & Dallière Industries
Setforge Electroforge
Setforge Estamfor
Setforge Extrusion
Setforge Gauvin
Setforge Hot Formers
Setforge L'Horme
Setforge La Clayette
Setforge Near Net

Technical Characteristics
Material*:
carbon steel C20 and C30
alloyed steel 20 MC5, 20MnCr5R, 20 /40 CD4, 20 CrMo4;
microalloyed steel 35 MnSiV5;
precipitation hardening steel 15 5PH and 17 4 PH;
stainless steel 304L and 316L
*Please note that these are only some examples for the available grades.

Spectrum of Components:
components for every possible mechanical field (automotive, trucks, railways, off highway, etc…)
very large spectrum of grades
mechanical properties obtained at a reasonable cost, thanks to adjustable heat treatment HT parameters
good machinability
cold forging ability for high-volume applications of steel types with carbon content below 0,5%
Non-Ferrous Alloys
Non-ferrous alloys have been recognized from many industries for their undoubted advantages.
Since non-ferrous are much lighter than ferrous ones, they are mainly preferred in configurations
where strength is needed, but weight is a factor (e.g. the aerospace industry). As their name
reveals they don't contain iron, which guarantees higher resistance to rust and corrosion. And
last, but not least non-ferrous metal are not-magnetic and therefore best choice for electronics
and wiring.

Setforge provides forged aluminum (1000, 2000, 5000, 6000 and 7000 series) with a diameter up
to 450 mm. Our expertise in the forging of light alloys includes further titanium and copper,
mainly used in the manufacture of swash plates for automotive air conditioning systems. Setforge
also works with nickel-based superalloys, especially designed for components, requiring high
temperature and high corrosion resistance. We carry out heat treatments (e.g. T0, T4, T6, T73),
finishing operations and tests in our workshops according to applicable specifications.

Our Expertise:
 Non-Ferrous Aerospace Component

Global Manufacturing
Setforge La Clayette

Technical Characteristics
Material*:
aluminum 2000, 6000, 7000 series
copper-based alloys
titanium-based alloys
Inconel 718 and 625
Nimonic (nickel-based alloys)

*Please note that these are only some examples for the available grades.

Spectrum of Components:
aircraft engine components
parts for the nuclear, chemical and navy industries
lightweight parts with high-fatigue strength for aeronautics (7000 series)
corrosion resistant parts for automotive applications in suspension parts (6000 series)
high-temperature and/or corrosion resistance of the applied superalloys
low-friction properties of copper parts
Do you need a similar component?