Forging is a metalworking process which involves hammering or pressing metal into high strength shapes and sizes. It is one of the oldest metalworking processes, dating back to ancient times when metal was first worked into simple tools, weapons and jewelry. Today, it is still an important process for many industrial applications due to its ability to create complex parts with high strength and durability.
Hot Forging
Hot forging involves heating the metal before it is formed. This increases its plasticity, making it easier to shape into complex shapes. Hot forging typically involves a press or hammer, which is used to shape the heated metal in a process known as upsetting. In this process, the preheated metal is forced into a die cavity in order to shape it into a desired shape. Hot forging is used in the production of parts for automotive, aerospace, and defense industries.
Cold Forging
Unlike hot forging, cold forging does not involve any heating of the metal prior to forming. The metal is formed by pressing it into the required shape at a temperature below its re-crystallization point. This process is often done with multi-stage presses to produce complex shapes that cannot be formed by conventional hot forging processes. The cool temperature prevents the material from hardening immediately and allows for an extended forming period. Cold forging is often used to produce parts for medical, aerospace and electronics industries which require intricate shapes and profiles.
Warm Forging
Warm forging is a hybrid of hot and cold forging. The metal used in the process is preheated to a temperature between the two process ranges and is then formed under pressure. This method is often less energy-intensive than hot forging and allows for more control over the shape and size of the finished product. Warm forging is commonly used for precision parts and components, such as aerospace and automotive parts.
Drop Forging
Drop forging is similar to hot forging, but the metal is formed under direct impact rather than being forced into a die cavity. A hammer is dropped onto the metal from a height and forms it into a desired shape. This process is often used to produce parts for machinery and hand tools, due to its ability to produce parts with high strength and accuracy.
Upset Forging
Upset forging is another type of hot forging process. In this process, the metal is heated and then compressed between two dies. This process is used to reduce the metal’s cross sectional area and create a desired shape. Upset forging is often used to produce parts with complex geometries and profiles that cannot be formed by other forging processes.
Extrusion Forging
Extrusion forging is a specialized hot forging process. In this process, the metal is heated and forced through a die in order to create a desired shape. This process is often used for producing parts for highly specialized applications, such as medical implants and automotive components.
Impression Die Forging
Impression die forging is a hot forging process which involves heating the metal and then forcing it into a die cavity using a hammer or press. The cavity of the die deforms the metal into the desired shape. This process is commonly used to produce automotive and aerospace parts due to its high accuracy and strength.
Cold Upset Forging
Cold upset forging is a cold forging process in which the metal is forced into a die at a lower temperature than is used in hot forging. This process is often used to produce parts with complicated shapes and profiles that require high accuracy and strength.
Overall, forging is a metalworking process that has been around for centuries and remains an essential process for many industries due to its ability to create parts with high strength and durability. There are a variety of forging processes, each one suited for a specific application. Each type of forging process has its own advantages and disadvantages, and it is important to select the one that best suits the application in terms of strength, accuracy and cost.
