FORGING

Forging is a metal working process in which useful shape is

obtained in solid state by hammering or pressing metal.

Classification of Forging Processes

Based on Temperature of the work piece:
 Hot Forging (most widely used)- Forging is carried out at a
temperature above the recrystallization temperature of the
metal.
• Cold Forging - Forging is carried out at a temperature below
the recrystallization temperature of the metal.
 ADVANTAGES/ DIS ADVANTAGES OF HOT & COLD FORGING

HOT FORGING COLD FORGING

ADVANTAGES ADVANTAGES
• High strain rates and hence easy • Less friction between die surface
flow of the metal and work piece
• Recrystallization and recovery are • Lubrication is easy
possible • No oxidation or scaling on the work
• Forces required are less and Good surface finish
DIS ADVANTAGES DIS ADVANTAGES
• Lubrication is difficult at high • Low strain rates, hence less
temperatures reduction.
• Oxidation and scaling occur on • Recrystallization and recovery
the work do not occur.
• Poor surface finish • Hence, annealing is required
• Dies must withstand high for further deformation in
working temperature subsequent cycles.
• Forces required are high.
 FORGING PROCESS
In this process the desired shape is obtained by the application of a compressive force
over the metal. In hot forging process the metal is heated above the recrystallization
temperature. This hot metal is then compressed to the desired shape using hammer
or press tool.

There are three types of forging process.

• Open die forging process
• Closed die forging process
• Roll forging process

OPEN DIE FORGING

In this type of forging process the work piece is heated to a very high temperature
and it is placed on a flat surface and hit using a hammer to obtain the desired
shape. This type of forging is very simple and flexible. It is very much useful in
producing rough components like chisel, bolts, and rectangular, circular, hexagonal
shapes. In this the forging hit is given either by hand or by power.
CLOSED DIE FORGING

1. DROP FORGING
The impression dies used in this process is called as closed dies. The upper die is fitted on the
ram and the lower die is fitted on the anvil. Both the dies have impression. Two rollers are
held on the board supporting the ram. These rollers rotate in opposite direction to each other.
This makes it to drive the board upwards and lifts the ram. By releasing the rollers the ram
falls down producing the working stroke. For producing simple parts a single stroke is enough.
large components are produced by number of steps.
APPLICATIONS
It is generally used for making spanner, automobile parts, and machine parts.
2. PRESS FORGING
Press forging is done with the help of a press. The press may either be operated mechanically
or hydraulically. It is a slow squeezing process rather than delivering heavy blows. The lower
die is fitted with the anvil and the upper die is fitted with the ram. The ram is slowly a moved
down and it slowly presses the metal. The finished component may be removed from the die
with the help of ejectors in the die set. The speed of press forging varies from 34 to 40 strokes
per minute.
APPLICATION
Press forging is used for making components such as connecting rods, machining
components, spanner, etc.
3. UPSET FORGING
This process is generally used to make head of bolts, rivets or pins. The shape of
the head may be square, hexagonal or hemispherical. The machine holds a die
set which consists of a fixed die and movable punch. The heated metal bar is
held in the die and the force is given to the punch. So the desired shape is
obtained with the help of die cavity.

ROLL FORGING
The roll forging machine consists of two horizontal rolls. The heated metal bar is
passed between the two rolls. Roll forging is performed in an impression-die.
A bar of heated rod is passed between the rolls. As the rolls rotate the heated
metal is squeezed between them. This method is used for reducing the cross
sectional area and for producing taper ends.
 GENERAL HEALTH HAZARDS

Some general health hazards are caused as a result of contact between the pollutants and
the body. These hazards are as follows:
• Eye irritation.
• Headache.
• Nose and throat irritation.
• Irritability of respiratory tract.
• Gases like hydrogen sulphide, ammonia and mercaptans cause odour nuisance even at
low concentrations.
• High temperature can cause fatigue and dehydration.
• Chronic pulmonary diseases like Bronchitis and asthma, are aggravated by a high
concentration of SO2, NO2, particulate matter and photochemicals.
• Carbon monoxide combines with the hemoglobin in the blood and consequently
increases stress on those suffering from cardiovascular and pulmonary diseases.
• Dust particles cause respiratory disease. Diseases like silicosis, asbestosis etc. result from
specific dust.
• Hydrogen fluoride causes diseases of bone (fluorosis) and mottling of teeth.
• Certain heavy metals like lead, cadmium, mercury, chromium, nickel, manganese etc. enter
into body by inhalation, skin absorption and through food chain. They cause acute and
chronic poisoning.
 FORGING OPERATION HAZARDS

No Hazards Example
1 Caught in between objects For power press, punching and forming For press brake, the stock ‘whips’ or
bends up and can cause the operator’s hand to be caught in between the
stock and the slide

2 Cut by sharp edges Loading and unloading the material can cause cuts

3 Struck by falling objects Die drops during set up

4 Struck by flying objects Chips released during punching can hit operators

5 Struck by moving objects For press brake, the stock ‘slaps’ the operator if he is in the path of the rising
material

6 Drag towards danger zone / Loading and unloading at automatic feeder

entanglement

7 Excessive noise / vibration Power presses are inherently noisy and the noise level can be as high as
95-115 dB(A) • Sources of noise are pneumatic and mechanical
• Vibration is related to noise and it is the cause of the mechanical noise
• Wear and tear of machine and die can be a source of noise

8 Energy source failure: electrical, • Failure of single stroke linkage • The loss of air pressure to the clutch/ brake
mechanical, hydraulic and • Presence sensing device power failure
pneumatic

9 Unsafe work behavior Guards and devices are by-passed to increase production • Two-hand
controls are bridged to allow initiation with one hand • Two-hand controls
are activated with the help of co-workers • Failure to isolate or de-activate
energy sources and lockout / tag out before employee performs servicing and
maintenance works • Devices are not properly adjusted • Devices are muted
No Hazards Example

10 Poorly designed Barrier not designed according to Safety Distance

guarding/ devices design Requirement • Part of the presence-sensing devices are
and poor maintenance muted by design • Safety devices and guardings are not
properly maintained. Workers tend to assume that the
safety devices and guardings work. But when they fail
without the knowledge of the workers, severe accidents
may happen.

11 Fatigue due to working Working long hours can affect concentration. During peak
long hours demand period, workers tend to work long hours. For
maintenance staff, sometimes extremely urgent repairs
may require them to work unlimited long hours. Without
control, this type of working pattern can be very
hazardous.
 PREVENTIVE MAINTENANCE OF FORGING MACHINES
Once punchers, shears, and benders are activated, it is impossible to stop them until the end of a
cycle. Use extreme care when working with these tools.
Inspection and maintenance:
All forge shop equipment must be maintained in a condition which will insure continued safe
operation
Hammers and presses:
All hammers must be positioned or installed in such a manner that they remain on or are anchored to
foundations sufficient to support them according to applicable engineering standards.
Hammers:
Die keys and shims must be made from a grade of material that will not unduly crack or splinter.
Presses:
All manually operated valves and switches must be clearly identified and readily accessible.
Power-driven hammers:
Every steam or air hammer must have a safety cylinder head to act as a cushion if the rod should
break or pull out of the ram.
Gravity Hammers:
Air-lift hammers must have a safety cylinder head.
Forging and trimming presses:
When dies are being changed or maintenance is being performed on the press, ensure the
following:
The power to the pressure is locked out
The flywheel is at rest.
The ram is blocked with a material of the appropriate strength.
Upsetters:
All upsetters must be installed so that they remain on their supporting foundations.
 HEAT RADIATION HAZARD & CONTROL
HAZARD FACTOR EFFECTS
• HIGH AMBIENT TEMPERATURE FATIGUE, HEAT STRESS, HEAT STRAIN
SURROUNDING THE FURNACE UNCOMFORTNESS, DEHYDRATION

• CONTACT WITH HOT METAL HEAT EXHAUSTION, REDUCED

INCLUDING INDIRECT CONTACT OF PHYSICAL ACTIVITY HEAT CATARACT
INFRA RED RADIATION FROM HOT METAL

• EYE INJURY DUE TO GLARE CAUSED EYE IRRITATION, FOREIGN BODY PENETRATION
METAL FUMES AND RADIATION INJURY TO RETINA AND DAMAGE TO THE LENSE
LEADING TO CATARACT
PREVENTIVE MEASURES
• Use of shield made of lead
• Monitoring of atmosphere
• Avoiding exposure to radiation
• Monitoring of individuals and working condition
• Periodic radiation examination
 SAFE WORK PRACTICE OF FORGE
• Use purpose-built material handling machines such as overhead cranes and forklifts with adequate
capacity and capability to load tools and die sets onto the machine.
• Only trained and authorised personnel may operate the material handling machine.
• Keep away from the transportation path of the lifted tool and die set, and do not stay or move below a
suspended tool and die set.
• Apply lockout procedures while fastening the tool and die onto a machine. The use of safety blocks is
encouraged.
• Only trained and authorised technicians can perform the tool and die set-up.
• Checks should be conducted upon the completion of the setup to ensure the tool and die are securely
mounted.
• If a setting bar is used as a lever to rotate the press crankshaft, it must have a spring loaded device to
ensure it cannot be left unintentionally in the crankshaft during setup.
• Any further adjustments to the tool and die after the set-up will have to be performed by trained and
authorised technicians with the application of lockout procedures.
• All safety devices provided on the press must be operational and correctly set before making a trial
pressing or adjusting the tool and die.
• Before commencing operation, functionality checks shall be performed for all safety devices on the power
press and the material feeder. Examples of such safety devices include machine guards, presence-sensing
device, two-hand operation devices, interlocking devices and emergency stop pushbuttons
• Care should be taken when handling materials with sharp edges. Cut resistant gloves should be used.
• Care should be taken while handling heavy materials. Adopt proper material lifting postures and use
mechanical aids when materials are too heavy for safe manual lifting.
• Ensure that the machine is at a complete stop before any work piece is loaded onto the die set.
• Ensure that no hands or any other part of the body is within the operational zone before activating the
machine.
 SAFETY PRECAUSIONS IN FORGING SHOP
Always avoid the use of damaged hammers.
Never try to strike a hardened surface with a hardened tool.
No person should stand in line with the flying objects.
Always use the proper tongs tool to grip and lift objects according to the type of work.
The anvil should always be clean and free from moisture and grease while in use.
Always wear proper clothes such as apron, foot-wears and goggles.
The handle of the hammer should always be tightly fitted in the head of the hammer.
Always put out the fire in the forge before leaving the forging shop.
Always keep the working space clean and tidy.
Proper safety guards should be provided on all revolving parts.
Head of the chisel should be free from burrs and should never be allowed to spread.
During machine forging, always observe the safety rules prescribed for each machine.
One must have the thorough knowledge and working of the forging machine before
going to operate it.