The Different and Important Types of Forging Processes

The different varieties of forging processes and procedures may be used for producing forgings of varying weight, size, and configurations. While some of these may use heat, some may use compression only.

The industrial and manufacturing process of forging involves turning/alloys metals into essential components and parts by applying a huge compressive force. These forgings are used today in a wide variety of industries, including the oil and gas industry, aerospace, agriculture, defense, and many others. With the advancement in technology and the passage of time, there are multiple methods of forging available today.

Important forging methods are described below.

1) Impression Die Forging/Closed Die Forging

The impression die forging method involves pressing or pounding of the metal in between two dies having a predefined shape and size of the forged part that is required. It is also called as tooling. Parts and components weighing up to 60,000 pounds can be made through the method. For the smaller components, the cold forging process may be used.

The impression die forging process can produce an endless variety of parts that may weigh up to 25 tons. These 3D shapes and varieties may be made by using materials including titanium, aluminium, steel, and other kinds of alloys. Mechanical presses, hydraulic presses, and hammers may be used to produce forgings through this method, and these methods may have capacity varying between 20,000 pounds to 50,000 pounds. The die controls the metal flow, and the more complex shapes and geometric varieties may also be produced through the method. Other allied operational procedures, including bending, may help manufacturers reach the desired symmetries, and a hollow forgingcan also be produced through the method.

2) Cold Forging

The cold forging procedure may produce parts without the application of heat, but in some cases. The processes involved in a cold forging procedure may include bending, cold drawing, joining of headings, the addition of extrusions, and many others to produce a wide variety of equipment and component. The cold forging procedure may be carried out at room temperature and also at temperatures up to several hundred-degree Fahrenheit. The process involves the insertion of lubricated bar slugs within a closed die. Extreme pressure is applied so that the material flows into the die and takes the desired shape.

3) Open Die Forging

In the open die forging method, there are no pre-cut dies. Hence the work piece has to move so that it can take the requisite and desired shape. Large parts having a length of up to 80 feet and a weight up to 200,000 pounds can be forged through this procedure. This process may have many more variations because widest varieties of forged components and parts can be produced and manufactured. The “size” related capability of this procedure can be the highest, and hence largest of equipment can be produced through the open die forging method.

4) Rolled Ring Forging

The rolled-ring forging or the seamless rolled-ring forging procedure involves the punching of a hole into a round and thick piece of metal. When the requisite doughnut shape is created, it is squeezed and rolled to take the form of a ring. The diameters of the ring may be up to 30 feet, and they may weight up to 3, 00,500 thousand pounds. The forging may be the best for industrial sectors, including mining, energy generation, aerospace, and other industries with more critical applications.

5) Press Forging

Press forging involves the use of a stationary die, and the forming factor is the compressive force applied to the metal or alloy. The force may be applied here for a longer period. Hence the contact time of the metal with force is longer. Therefore, not only a localized section but the entire part/component can be manufactured through compression using this method in one go.

Different kinds of forging methods and procedures can be used for producing forges for specific purposes and industries. Talking to a leading manufacturer and supplier will help you procure your industry's forgings of the highest quality and strength.