EDPT 604

Metal Forming Processes and Machines

Lecture 3
Metal Forging

Metal Forging Process

Dr. Mohamed Harraz

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Introduction Forging Process

Forging is one of the oldest known metalworking processes. Traditionally,
forging was performed by a smith using hammer and anvil, and though the use of
water power in the production and working of iron dates to the 12th century, the
hammer and anvil are not obsolete. Forging can be defined as a manufacturing
process involving the shaping of metal using localized compressive forces.
Forging is often classified according to the temperature at which it is performed:
"cold", "warm", or "hot" forging. Forged parts can range in weight from less than
a kilogram to 580 metric tons. Forged parts usually require further processing to
achieve a finished part.
In modern times, industrial forging is done either with presses or with hammers
(see next slide) powered by compressed air, electricity, hydraulics or steam.
These hammers may have reciprocating weights in the thousands of kilos.
Smaller power hammers power, 230 kg or less reciprocating weight, and
hydraulic presses are common in art smithies as well. Some steam hammers
remain in use, but they became obsolete with the availability of the other, more
convenient, power sources.
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Dr. Mohamed Harraz

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Press Hammers

Power press with a fixed

barrier guard
Power hammers are mechanical forging hammers that use a non-muscular
power source to raise the hammer preparatory to striking, and accelerate it
onto the work being hammered. Also called "Open Die Power Forging
Hammers." They have been used by blacksmiths, metalworkers, and
manufacturers since the late 1880s.
Metal Forging Process

Dr. Mohamed Harraz

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Process and Advantages

Forging is suitable for
one-offs and low volume
production as well as mass
production runs.
The drop forging process
is particularly used in
safety critic applications.
At low volumes forging
provides an alternative to
machining, where as at
high volumes it competes
with casting.

Drop Forging Process

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Dr. Mohamed Harraz

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Quality of Drop Forging

By its very nature, forging improves grain structure in the finished part. Metal
billets go through plastic deformation as theyre forged and as a result the metal
grains align in the direction of flow. This characteristic produces exceptional
strength to weight properties and reduces stress concentrations that tend to occur
in corners and fillets. Parts can be machined post-forging with no loss of quality,
because there are no voids or porosity in the finished article. The tolerances
range from 1 mm in small parts up to 5 mm in large parts, but vary according to
requirements, because reducing tolerances increases costs. Forging is often
combined with machining for improved accuracy. Cold coining or sizing in
house can also close tolerances and reduce the need to machine some parts.
This process is suitable for low volume production as well as one-offs. This is
because it produces parts with superior strength to weight properties that cannot
be manufactured in any other way. Small volumes can be machined from solid,
but they will have to compensate for reduced strength brought about by random
grain alignment. Undercuts are not possible in forging, however, it is possible to
form undercuts and form joints with secondary forging operations
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Dr. Mohamed Harraz

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Hot and Cold Working

Hot working refers to processes where metals are plastically deformed above
their recrystallization temperature. Being above the recrystallization temperature
allows the material to recrystallize during deformation. This is important because
recrystallization keeps the materials from strain hardening, which ultimately
keeps the yield strength and hardness low and ductility high.
Cold working also known as Work hardening or strain hardening, is the
strengthening of a metal by plastic deformation. This strengthening occurs
because of dislocation movements within the crystal structure of the material. Any
material with a reasonably high melting point such as metals and alloys can be
strengthened in this fashion.
Some metals may be forged cold, but iron and steel are almost always hot forged
. Hot forging prevents the work hardening that would result from cold forging,
which would increase the difficulty of performing secondary machining
operations on the piece. Also, while work hardening may be desirable in some
circumstances, other methods of hardening the piece, such as heat treating, are
generally more economical and more controllable.
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Dr. Mohamed Harraz

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Effect of open die forging process

on the crystal structure

During this hot forging process, the cast, coarse grain structure is broken up and
replaced by finer grains. Low-density areas, micro-shrinkage and gas porosity inherent
in the cast metal are consolidated through the reduction of the ingot, achieving sound
centers and structural integrity. Mechanical properties are therefore improved through
the elimination of the cast structure, enhanced density, and improved homogeneity.
Forging also provides means for aligning the grain flow to best obtain desired
directional strengths. Secondary processing, such as heat treating, can also be used to
further refine the part.
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Dr. Mohamed Harraz

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Multistep forging process

Scheme of the isothermal multistep forging process.

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Dr. Mohamed Harraz

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Open and Closed die Forging

Open-die forging

Closed-die forging
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Flash vs. flashless closed die forging

Trimming Flash
by punching

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Die inserts closed die forging

Die inserts used for forging an automotive axle

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Open Die Forging

What is Open Die Forging?
Open die forging is a forging process that forged the metal in an open mold. Open die
forging products usually have a flash. The flash of forgings needs to be trimmed by press
cutting machine. Both hot forging and cold forging can use open die forging process.
Open die forging products require cutting, machining and polishing services.
What materials were used for Open Die Forging?
The materials of open die forging and closed die forging are basically the same. They
could forge a variety of types of materials. The most common materials are carbon steel,
alloy steel, stainless steel and copper alloy.
Features of Open Die Forging
1. Compared with drop forging, open-die forging products could make the shape in one
time and have a good quality.
2. Open die forging could improve the production efficiency for the parts which do not
required high precision.
3. Compared with the closed die forging, open die forging products require further
machining to remove the flash.
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Examples of open die-forged parts

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Dr. Mohamed Harraz

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Closed Die Forging

What is Closed Die Forging?
Closed die forging is a forging process that demands high precision and one-time forming
shape. In some aspects, closed die forging is similar to precision forging. Closed-die
forgings can be done without flash. This greatly improved working efficiency and reduced
material costs. Closed die forging was also called impression die forging. Sometimes closed
die forging used two or more molds to forge the metal. This will help the forging products
directly to its final shape without flash.
Materials used for Closed Die Forging
The materials of closed die forging and open die forging are basically the same. The most
common materials are carbon steel, alloy steel, stainless steel and copper alloy.
Features of closed die forging
1. The closed die forgings have high strength and precision surface treatment. Usually
closed die forgings do not need machining process.
2. Closed die forging need high precision molds. This is the most important part in closed
die forging.
3. For some forging products, closed die forging could save raw materials and reduce the
products cost.
Metal Forging Process

Dr. Mohamed Harraz

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Examples of closed die-forged parts

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Dr. Mohamed Harraz

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Cogging (drawing out)

Cogging operations are simple to set up
and allow the use of separate top and
bottom dies. A cogging operation can be
set up in a single action with the
movement and rotation of the billet
entered in a simple table that also
accounts for the cooling of the billet
between blows and while resting on the
bottom die.
The billet can be held in place relative
to either die or with a downward speed
equal to half the speed of the top die to
simulate any type of manipulator. The
manipulator can be set up to allow for
axial movement as the material is
compressed.

Linear motion and rotation

in cogging operation

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Closed die forging

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Heading (upset forging)

Open die

Closed die

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End

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