Forging is one of the oldest metalworking processes and is used today to manufacture everything from jewelry to turbine blades for aircraft engines. Depending on the specific part that is being produced, the forging process can involve one or more of a number of different steps, including:
1. Design: Engineering the part in its initial state, either on paper or through a computer-generated model.
2. Heating: High-temperature heating of the raw material, either in a furnace or with an induction heating system, in order to make it more malleable.
3. Blanking: Cutting the heated material into a blank, the shape of which will become the finished part.
4. Pre-forging: Performing an initial forging operation to put the material in a more workable state.
5. Final forging: Achieving the desired shape, size, and tolerances of the part through a series of successive forging operations.
6. Coining: Producing raised surfaces or specific detail on the surface of the part using a press.
7. Finishing and Quality Assurance: Ensuring that the desired features are present and accurate, as well as inspecting for any flaws or imperfections.
8. Heat treatment: Applying heat to polish or change the strength or other properties of the finished part.
9. Plating, Paint, or Epoxy: Applying a protective finish to the part to increase its durability and corrosion-resistance.
Each of these steps can involve extensive consideration of the material being used, the geometry of the part, and the finished characteristics of the component depending on its intended use. Forging operations are incredibly precise and require highly skilled professionals as well as quality control measures throughout the process.
Forging can create parts with better mechanical properties than many alternatives, as well as allow for greater design complexity, higher material utilization, and lower machining costs. There is also a variety of potential defects that can occur during the forging process, which must be monitored and evaluated in order to ensure quality. Forging provides a unique combination of attributes that make it suited for a variety of applications.
