Forging is a process of shaping metals through compression, commonly used in the automotive, aerospace and construction industries. The process involves putting an object, usually a metal rod or a sheet of metal, under extremely high pressure to cause it to deform plastically and take the desired shape. The process has been used since the Bronze Age and has seen developments in technology and materials technology that have allowed for simpler shapes to be formed more quickly and accurately.
There are two main types of forgings: hot and cold. In hot forgings, the metal is heated in a furnace to very high temperatures and then shaped under pressure. This is typically done with large pieces of metal, such as engine blocks and structural beams, and is also often used to make car parts. In cold forgings, the metal is usually heated to lower temperatures than in hot forging and is then shaped on cold dies or moulds. Cold forging is often used to make small, intricate shapes that can’t be produced by other methods.
The process of forging is usually carried out in a forge, a workshop or factory with specialised equipment. For example, a large press can be used to provide the necessary pressure, while a hammer and anvil can be used to shape and bend smaller pieces of metal. In some cases, particularly for larger pieces of metal, a hydraulic forging hammer, or stamping press, is used to deliver the necessary pressure.
The advantages of forging over other manufacturing methods include its affordability, accuracy, and strength. Forging is also a more efficient process, as it produces a more uniform product and fewer waste materials than other methods such as die-casting. Additionally, the process is able to produce complex shapes without the need for additional finishing, such as machining, grinding or polishing.
However, there are some downsides to the forging process. It is labour-intensive, requiring skilled workers to operate and maintain the machines, as well as experienced craftsmen to create the final product. Additionally, some metals are not suitable for forging, as they require specialised machinery and conditions. For example, titanium is difficult to form reliably through forging, as it requires very high temperatures to soften the metal enough to shape it.
Overall, forging is a process with a long history in the metals manufacturing industry, and is still widely used today to shape parts for a variety of applications. Its cost-effectiveness, accuracy, and strength make it a preferred method for producing components for automobiles, aircraft, and heavy machinery. Although it does require more time, attention, and money to operate than other manufacturing processes, the end product generally surpasses its competitors when it comes to strength and durability.
