Compare Forging Process to Machined Steel Bar /

Plate

Compare... Machined Steel Bar/Plate Forging

Forging is often the only metalworking option

Sizes and shapes of products made from available with certain grades in desired sizes.
Size range of
steel bar and plate are limited to the Forgings can be economically produced in a wide
desired material
dimensions in which these materials are range of sizes - from parts whose largest dimension
grades:
supplied. is less than 1 in. to parts weighing more than
450,000 lbs.

Machined bar and plate is more susceptible to
Strength of grain
fatigue and stress corrosion because
orientation:
machining cuts material grain pattern.
Forging yields a grain structure oriented to the part
shape, resulting in optimum strength, ductility and
resistance to impact and fatigue.

Flame cutting plate is a wasteful process -

one of several fabricating steps that
Economical use of Material cost savings can be significant, whether
consumes more material than needed to
materials: aluminum, steel or special alloy forging is applied.
make parts such as rings or hubs. Even more
is lost in subsequent machining.
 Better use of material, especially for near net shape
Rate of scrap and Because of the inherent waste to the steel bar
forgings, generates little scrap. In high-volume
cost-effectiveness and plate machining process, there is always
production runs, forgings have the decisive cost
of production: a high rate of scrap and loss in cost.
advantage.

Some grades of bar and plate require

additional operations - such as turning,
Requirement for
grinding and polishing - to remove surface On average, forgings can be put into service without
secondary
irregularities and achieve the desired finish, expensive secondary operations.
operations:
machinability, dimensional accuracy and
strength.

Compare and contrast machined steel bar and plate to forging – in terms of size range, grain orientation
strength, use of materials, scrap and production, and requirement for secondary operations.