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8/1/2015 Types of Forging Processes | Forging Industry Association https://www.forging.org/typesforgingprocesses 1/4 Home Types of Forging Processes Login Contact Us Site Map Search Entire Site... Types Of Forging Processes Producers & Suppliers Designers & Buyers Students & Academia Government & Media Forging Videos There are basically three methods (or processes) to make a forged part. 1. Impression Die Forging 2. Cold Forging 3. Open Die Forging 4. Seamless Rolled Ring Forging Impression Die Forging Impression die forging pounds or presses metal between two dies (called tooling) that contain a precut profile of the desired part. Parts from a few ounces to 60,000 lbs. can be made using this process. Some of the smaller parts are actually forged cold. PROCESS OPERATIONS Graphical depiction of process steps. Still Graphic Animated Sequence Video Process Capabilities Commonly referred to as closeddie forging, impressiondie forging of steel, aluminum, titanium and other alloys can produce an almost limitless variety of 3D shapes that range in weight from mere ounces up to more than 25 tons. Impressiondie forgings are routinely produced on hydraulic presses, mechanical presses and hammers, with capacities up to 50,000 tons, 20,000 tons and 50,000 lbs. respectively. As the name implies, two or more dies containing impressions of the part shape are brought together as forging stock undergoes plastic deformation. Because metal flow is restricted by the die contours, this process can yield more complex shapes and closer tolerances than opendie forging processes. Additional flexibility in forming both symmetrical and non symmetrical shapes comes from various preforming operations (sometimes bending) prior to forging in finisher dies. Part geometry's range from some of the easiest to forge simple spherical shapes, blocklike rectangular solids, and disclike configurations to the most intricate components with thin and long sections that incorporate thin webs and relatively high vertical projections like ribs and bosses. Although many parts are generally symmetrical, others incorporate all sorts of design elements (flanges, protrusions, holes, cavities, pockets, etc.) that combine to make the forging very nonsymmetrical. In addition, parts can be bent or curved in one or several planes, whether they are basically longitudinal, equidimensional or flat. Most engineering metals and alloys can be forged via conventional impressiondie processes, among them: carbon and alloy steels, tool steels, and stainless, aluminum and copper alloys, and certain titanium alloys. Strainrate and temperaturesensitive materials (magnesium, highly alloyed nickelbased superalloys, refractory alloys and some titanium alloys) may require more sophisticated forging processes and/or special equipment for forging in impression dies. Click on the video links below to learn more about the forging industry: View All Home FIA About Forging FIERF Benchmarking Forge Shop Info Career Center Member Services Forge Fair

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  • 8/1/2015 TypesofForgingProcesses|ForgingIndustryAssociation

    https://www.forging.org/typesforgingprocesses 1/4

    Home TypesofForgingProcesses

    Login ContactUs SiteMap

    SearchEntireSite...

    TypesOfForgingProcessesProducers&Suppliers

    Designers&Buyers

    Students&Academia

    Government&Media

    ForgingVideos

    Therearebasicallythreemethods(orprocesses)tomakeaforgedpart.

    1. ImpressionDieForging

    2. ColdForging

    3. OpenDieForging

    4. SeamlessRolledRingForging

    ImpressionDieForgingImpressiondieforgingpoundsorpressesmetalbetweentwodies(calledtooling)thatcontainaprecutprofileofthedesiredpart.Partsfromafewouncesto60,000lbs.canbemadeusingthisprocess.Someofthesmallerpartsareactuallyforgedcold.

    PROCESSOPERATIONSGraphicaldepictionofprocesssteps.

    StillGraphicAnimatedSequenceVideo

    ProcessCapabilities

    Commonlyreferredtoascloseddieforging,impressiondieforgingofsteel,aluminum,titaniumandotheralloyscanproduceanalmostlimitlessvarietyof3Dshapesthatrangeinweightfrommereouncesuptomorethan25tons.Impressiondieforgingsareroutinelyproducedonhydraulicpresses,mechanicalpressesandhammers,withcapacitiesupto50,000tons,20,000tonsand50,000lbs.respectively.

    Asthenameimplies,twoormorediescontainingimpressionsofthepartshapearebroughttogetherasforgingstockundergoesplasticdeformation.Becausemetalflowisrestrictedbythediecontours,thisprocesscanyieldmorecomplexshapesandclosertolerancesthanopendieforgingprocesses.Additionalflexibilityinformingbothsymmetricalandnonsymmetricalshapescomesfromvariouspreformingoperations(sometimesbending)priortoforginginfinisherdies.

    Partgeometry'srangefromsomeoftheeasiesttoforgesimplesphericalshapes,blocklikerectangularsolids,anddisclikeconfigurationstothemostintricatecomponentswiththinandlongsectionsthatincorporatethinwebsandrelativelyhighverticalprojectionslikeribsandbosses.Althoughmanypartsaregenerallysymmetrical,othersincorporateallsortsofdesignelements(flanges,protrusions,holes,cavities,pockets,etc.)thatcombinetomaketheforgingverynonsymmetrical.Inaddition,partscanbebentorcurvedinoneorseveralplanes,whethertheyarebasicallylongitudinal,equidimensionalorflat.

    Mostengineeringmetalsandalloyscanbeforgedviaconventionalimpressiondieprocesses,amongthem:carbonandalloysteels,toolsteels,andstainless,aluminumandcopperalloys,andcertaintitaniumalloys.Strainrateandtemperaturesensitivematerials(magnesium,highlyalloyednickelbasedsuperalloys,refractoryalloysandsometitaniumalloys)mayrequiremoresophisticatedforgingprocessesand/orspecialequipmentforforginginimpressiondies.

    Clickonthevideolinksbelowtolearnmoreabouttheforgingindustry:

    ViewAll

    Home FIA AboutForging FIERF Benchmarking ForgeShopInfo CareerCenter

    MemberServices ForgeFair

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    ColdForgingMostforgingisdoneashotwork,attemperaturesupto2300degreesF,however,avariationofimpressiondieforgingiscoldforging.Coldforgingencompassesmanyprocessesbending,colddrawing,coldheading,coining,extrusionsandmore,toyieldadiverserangeofpartshapes.Thetemperatureofmetalsbeingcoldforgedmayrangefromroomtemperaturetoseveralhundreddegrees.

    ProcessOperationsGraphicaldepictionofprocesssteps.

    ProcessCapabilities

    Coldforgingencompassesmanyprocessesbending,colddrawing,coldheading,coining,extrusion,punching,threadrollingandmoretoyieldadiverserangeofpartshapes.Theseincludevariousshaftlikecomponents,cupshapedgeometry's,hollowpartswithstemsandshafts,allkindsofupset(headed)andbentconfigurations,aswellascombinations.

    Mostrecently,partswithradialflowlikeroundconfigurationswithcenterflanges,rectangularparts,andnonaxisymmetricpartswith3and6foldsymmetryhavebeenproducedbywarmextrusion.Withcoldforgingofsteelrod,wire,orbar,shaftlikepartswith3planebendsandheadeddesignfeaturesarenotuncommon.

    Typicalpartsaremostcosteffectiveintherangeof10lbs.orlesssymmetricalpartsupto7lbs.readilylendthemselvestoautomatedprocessing.Materialoptionsrangeformloweralloyandcarbonsteelsto300and400seriesstainless,selectedaluminumalloys,brassandbronze.

    Therearetimeswhenwarmforgingpracticesareselectedovercoldforgingespeciallyforhighercarbongradesofsteelorwhereinprocessannealscanbeeliminated.

    Oftenchosenforintegraldesignfeaturessuchasbuiltinflangesandbosses,coldforgingsarefrequentlyusedinautomotivesteeringandsuspensionparts,antilockbrakingsystems,hardware,defensecomponents,andotherapplicationswherehighstrength,closetolerancesandvolumeproductionmakethemaneconomicalchoice.

    Intheprocess,achemicallylubricatedbarslugisforcedintoacloseddieunderextremepressure.Theunheatedmetalthusflowsintothedesiredshape.Asshown,forwardextrusioninvolvessteelflowinthedirectionoftheramforce.Itisusedwhenthediameterofthebaristobedecreasedandthelengthincreased.Backwardextrusion,wherethemetalflowsoppositetotheramforce,generateshollowparts.Inupsetting,themetalflowsatrightanglestotheramforce,increasingdiameterandreducinglength.

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    OpenDieForgingOpendieforgingisperformedbetweenflatdieswithnoprecutprofilesisthedies.Movementoftheworkpieceisthekeytothismethod.Largerpartsover200,000lbs.and80feetinlengthcanbehammeredorpressedintoshapethisway.

    PROCESSOPERATIONSGraphicaldepictionofprocesssteps.

    StillGraphic

  • 8/1/2015 TypesofForgingProcesses|ForgingIndustryAssociation

    https://www.forging.org/typesforgingprocesses 3/4

    AnimatedSequenceVideo

    ProcessCapabilities

    Opendieforgingcanproduceforgingsfromafewpoundsuptomorethan150tons.Calledopendiebecausethemetalisnotconfinedlaterallybyimpressiondiesduringforging,thisprocessprogressivelyworksthestartingstockintothedesiredshape,mostcommonlybetweenflatfaceddies.Inpractice,opendieforgingcomprisesmanyprocessvariations,permittinganextremelybroadrangeofshapesandsizestobeproduced.Infact,whendesigncriteriadictateoptimumstructuralintegrityforahugemetalcomponent,thesheersizecapabilityofopendieforgingmakesittheclearprocesschoiceovernonforgingalternatives.Atthehighendofthesizerange,opendieforgingsarelimitedonlybythesizeofthestartingstock,namely,thelargestingotthatcanbecast.

    Practicallyallforgeableferrousandnonferrousalloyscanbeopendieforged,includingsomeexoticmaterialslikeagehardeningsuperalloysandcorrosionresistantrefractoryalloys.

    Opendieshapecapabilityisindeedwideinlatitude.Inadditiontoround,square,rectangular,hexagonalbarsandotherbasicshapes,opendieprocessescanproduce:

    Stepshaftssolidshafts(spindlesorrotors)whosediameterincreasesordecreases(stepsdown)atmultiplelocationsalongthelongitudinalaxis.Hollowscylindricalinshape,usuallywithlengthmuchgreaterthanthediameterofthepart.Length,wallthickness,IDandODcanbevariedasneeded.Ringlikepartscanresemblewashersorapproachhollowcylindersinshape,dependingontheheight/wallthicknessratio.Contourformedmetalshellslikepressurevessels,whichmayincorporateextrudednozzlesandotherdesignfeatures.

    Notunlikesuccessiveforgingoperationsinasequenceofdies,multipleopendieforgingoperationscanbecombinedtoproducetherequiredshape.Atthesametime,theseforgingmethodscanbetailoredtoattaintheproperamountoftotaldeformationandoptimumgrainflowstructure,therebymaximizingpropertyenhancementandultimateperformanceforaparticularapplication.Forginganintegralgearblankandhub,forexample,mayentailmultipledrawingorsolidforgingoperations,thenupsetting.Similarly,blanksforringsmaybepreparedbyupsettinganingot,thenpiercingthecenter,priortoforgingthering.

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    SeamlessRolledRingForgingSeamlessrolledringforgingistypicallyperformedbypunchingaholeinathick,roundpieceofmetal(creatingadonutshape),andthenrollingandsqueezing(orinsomecases,pounding)thedonutintoathinring.Ringdiameterscanbeanywherefromafewinchesto30feet.

    PROCESSOPERATIONSGraphicaldepictionofprocesssteps.

    StillGraphicAnimatedSequenceVideo

    ProcessCapabilities

    Ringsforgedbytheseamlessringrollingprocesscanweigh


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