Forging has been used for centuries to produce tools, weapons, and other objects of utility or decoration. Although forging has been used since ancient times, its advantages over modern production methods can make it a great choice for your product.
This blog will discuss what forging is, how it works, and how it can benefit your product. We’ll also look at examples of popular products that use the forging process and how they can be leveraged in manufacturing metal products.
What Is Forging?
Forging is a metalworking process that involves heating metal and hammering or forming it into the desired shape. The temperature of the metal must be above its recrystallization point, which is different for each type of metal. For example, steel can be forged at temperatures between 1,550 °F and 2,250 °F. Moreover, some metals and design requirements can use either the hot or cold forging process.
Forging can be done by hand or machine, such as press forges or drop hammers. Depending on what type of object you are creating, either method may be used
How Does Forging Benefit Your Product?
Manufacturers can use forging to create various objects with different requirements and applications. Additionally, forging can also benefit products in the following ways:
Manufacturing Flexibility
With forging, you can create parts that have different shapes and sizes. This process is especially useful when creating complex shapes or irregular details, as it allows the component to be manufactured according to its exact specifications.
Structural and Impact Strength
Forged products are often more durable than items created through other manufacturing methods. Metal grain size is reduced during the forging process, and its atoms align along the direction of forming. This increases the product’s structural integrity so it can better withstand shocks and stress over time.
Better Quality
Forging can produce higher-quality components due to improved material properties. These include grain orientation, uniformity, fewer flaws, less porosity, and a better surface finish.
Lower Cost
Since forged products are of better quality, manufacturers effectively reduce the cost of repair or replacement due to defects or failure. Also with modern forging methods, including automation, forging provides a low cost manufacturing process that is cost competitive and oftentimes reduces overall machining time.
Different Types of Forging
There are several types of forging used to create metal products. Depending on the size and shape of the product you want to make, one type may be more suitable than another. Here is an overview of the most common forging methods:
Impression Die Forging
This process — also referred to as close die forging — requires two dies that match each other perfectly to shape a heated piece of metal into the desired shape. The dies are closed together with great force, causing the metal to take on the shape between them. Impression die forging is typically used for more complex shapes..
Open Die Forging
Open die forging does not use dies as closed die forging does. Instead, a single hammer is used to shape hot metal between two flat dies. This method is typically used for larger objects, such as ingots, shafts, and bars.
Upset Forging
Upset forging involves heating a piece of metal on one end of the bar and forging it on that end with a die or anvil to increase its length without changing its diameter. This type of forging is often used to create cylindrical parts with threads or other features along the length.
Seamless Rolled Ring Forging
Rolled ring forging involves passing the heated metal through two rollers to change its shape gradually. This method is often used to create long rods or tubes with intricate shapes that would be difficult to achieve with other methods.
Cold Forging
Extrusion, cold drawing, cold heading, coining, and bending are some techniques used in cold forging. This type can be more cost-effective since it does not require heat treatment and produces components with high-quality surface finishes and tight tolerance dimensions.
High-Quality Forging Services With Cornell Forge
Cornell Forge is an ISO 900:2015 certified company with expertise in forging metal products! Our highly experienced and expert workforce is more than capable of handling a wide array of products and complex parts. We also offer globally competitive pricing, consistent quality standards, and reliable delivery and turnaround times!
With 90 years of excellence to offer, you can rely on us for all your forging needs! Contact us to discuss your requirements today.