Forging
Forging is a process of forming metal parts by causing a plastic deformation at temperatures suitable for the desired material. Every part has a different forging process depending on its shape and type of material, but in general terms the forging process involves shaping a piece of heated metal by compressing or squeezing it into the desired shape. This process can be performed manually or by using a machine press and the method can also be combined with other processes such as heat treatment, machining, and surface treatment.
Forging is an ancient technique with a long history, and is still widely used today, especially in the automotive and aerospace industries. In some cases, the process produces parts with superior properties as compared to other methods. Forging can produce components with improved strength, toughness, uniformity, and ductility.
Forgings are produced in three different types; open-die, impression-die, and closed-die forging. In open-die forging, the piece is squeezed between flat dies using a hammer or press to shape the parts. When using the impression-die method, a pre-shaped tool is used to form the desired shape of the part. The closed-die method utilizes a die that is clamped together which will shape the part in one stroke. Working with each of these processes requires knowledge and experience to understand the process and how to optimize the final product.
Other forging processes include flashless forging and centrifugal forging. Flashless forging is used when using high ductility materials such as magnesium and aluminum, where it is necessary to form a part without the excess material that is bent into the shape of the part. Centrifugal forging is used to create parts with complex shapes, as the centrifugal forces involved allow the part to be formed into a desired shape through compression and impact.
To produce a forged part, the material is heated to the desired forging temperature and then placed into a die cavity. The die is then closed and the forging force is applied. The force causes the material to deform and take on the shape of the die cavity. After the forging process is completed, the part is then cooled either naturally or forced at a controlled rate to maintain its strength.
There are a wide range of advantages to using the forging process. The parts produced are typically stronger than those produced by other methods, as the concentrated deformation of the material allows the part to take on the shape and strength of the die cavity. The process can also reduce costs and improve efficiency, as the shape and size of the part is set in the forging design and requires little to no extra machining, cutting, or finishing.
Overall, forging is an ancient but reliable process with wide-ranging applications. The process allows for a part to be formed with superior strength and uniformity and without the need for additional machining. The process is also suitable for a wide range of materials, including steel, brass, and aluminum, and allows for the production of parts in various shapes and sizes. With these benefits, it is no wonder why forging is still a popular method in the production of parts.
