Forging

About Forging

Forging is the process by which metal is heated and is shaped by plastic deformation by suitably applying compressive force. Usually the compressive force is in the form of hammer blows using a power hammer or a press. Forging refines the grain structure and improves physical properties of the metal. Forgings are consistent from piece to piece, without any of the porosity, voids, inclusions and other defects. Thus, finishing operations such as machining do not expose voids, because there aren’t any. Also coating operations such as plating or painting are straightforward due to a good surface, which needs very little preparation.

Common Forging Processes

Open Die Forgings

Open die forgings or hand forgings are made with repeated blows in an open die, where the operator manipulates the work piece in the die. The finished product is a rough approximation of the die. This is what a traditional blacksmith does, and is an old manufacturing process.

Precision Forgings

Impression die forgings and precision forgings are further refinements of the blocker forgings. The finished part more closely resembles the die impression. We have pneumatic hammers for doing the Impression Die Forgings.

Press Forgings

Press forging use a slow squeezing action of a press, to transfer a great amount of compressive force to the work piece. Unlike an open-die forging where multiple blows transfer the compressive energy to the outside of the product, press forging transfers the force uniformly to the bulk of the material. 

Upset Forgings

Upset forging increases cross-section by compressing the length, this is used in making heads on bolts and fasteners, valves and other similar parts. We are backed up with Forging Up setters from 1.5 Inch to 15 Inch Dia.

Advantages of Forging Processes

Open Die Forgings

  • Better fatigue resistance and strength
  • Reduces chance of error and/or holes
  • Improves microstructure
  • Continuous grain flow

Precision Forgings

  • Produces parts up to 25 tons
  • Produces near net shapes that require only a small amount of finishing
  • Economic for heavy production

Press Forgings

  • Economic for heavy production
  • Dies have less draft allowing for better dimensional accuracy
  • Speed, pressure, and travel of the die are automatically controlled

Upset Forgings

  • High production rate of up to 4500 parts per hour
  • Full automation is possible
  • Elimination of the forging draft and flash
  • Produces little to no waste