GOVERNMENT COLLEGE OF ENGINEERING ,

KEONJHAR

DEPARTMENT OF MECHANICAL ENGINEERING

REPORT ON
FORGING

PRESENTED BY BRANCH-MECHANICAL ENGINEERING

1.BHAGYASHREE PARIDA (2201104127) YEAR-3 RD YEAR
2.BHARAT BHUSHAN MAHANTA (2201104128) 5 TH SEMESTER
3.DEBASIS BEHERA PRADHAN (2201104129)
4.JAGADANANDA MAHANTA (2201104131)
 Forging
CONTENTS
 Introduction to Forging
 Why we use Forging
 Classification of Forging
 Forging processes
 Types of Forging
 Operation in Forging process
 Advantages and disadvantages of Forging
 Defects in Forging
 Conclusion
Introduction to Forging

 Forging is a metal forming manufacturing process where raw metal is transformed

into desired shapes and forms through the application of compressive forces.
 The process can be performed at a range of temperatures from room temperature
to over 1000°C. Forging can also increase the strength of the metal.

Metals used In Forging :

 Typical metals used in the forging process include carbon, alloy steels, stainless
steel and copper alloys.
Why we use forging ?
Strength and Durability:
 Forged products exhibit exceptional strength and durability due to the compaction and realignment of the metal's internal structure.

Design Flexibility:
 Forging allows for the creation of complex shapes and geometries that are difficult to achieve through other metalworking methods.

Cost-Effectiveness:
 Forging is a highly efficient process that minimizes material waste, making it a cost-effective solution for large-scale production.

 This is why forgings are almost always used whose reliability and human safety and critical such as a aeroplane, automobiles, ships, oil drilling
equipment and engines.
 Classification of Forging
 Forging is often classified according to the temperature at which is performed.

Hot Forging Warm Forging Cold Forging

 Forging is carried out at above the  Temperature range of warm working is  Forging is carried at or near room
recrystallisation temperature of the above the room temperature but below temperature.
metal. the recrystallisation temperature of metal .  Cold forging is generally preferred
 High strain rates and hence metal  At higher temperature ductility of the when the metal is already soft ,like
can easily deform, less tolling forces metal is increased so required low tolling aluminium.
required. load.  End products requires little or no
 Oxidation and salling occurs , end  End product is with excellent dimensional finishing work and has good surface
product is with poor surface finish , tolerance and surface finish. finish.
less precise tolerances.
According to arrangement of Die:
Forging processes may be classified into 2 types:
1. Open die Forging
2. Closed die Forging

Open die Forging

• In open die forging, also called hammer forging or flat die forging.
• The workpiece is struck or passed between two flat surfaces.
• Open die forging is used where the number of components is forced
too small or where the sizes are too large or irregular.

Advantages:
• Little or no tooling cost
• Reduced lead time
• A variety of size options, from small to large
Disadvantages:
• Not suitable for forming intricate, precision parts or other close-tolerance applications
• Machining is often required to complete open-die forgings
 Closed die forging
• Closed die forging (also known as impression die forging) is a metal forming process
where a workpiece is shaped by hammering or squeezing it between custom-shaped dies.
• These dies completely enclose the material, resulting in precise and durable components.

Advantages:
• The internal grain structure formation increases the
tightness and strength of the products.
• No material limitation.
• Better surface finish.

Disadvantages:
• It is not very economical for short runs due to the high
cost of die production.
• Closed die forging presents a dangerous
working environment.
• The setup cost is very high as the machines and
furnaces are costly.
Classification of close die forging:

Drop Forging: Press Forging: Upset Forging/ machine Forging:

 Press forging is done in presses
 A hammer or press applies a  The metal is compressed axially, causing
rather than with hammer. In
single, high-energy blow to the it to expand radially and form the desired
press forging a slow squeezing
heated metal, shaping it into the shape.
action is used to transfer a
desired form.
great amount of compressive
force to the workplace.
Operation in Forging Process
1. Upsetting
2. Cogging
3. Fullering
4. Edging
5. Flattening
6. Swaging
7. Bending
8. Blocking
Upsetting:
 Upsetting is just the opposite operation to drawing down.
 In this operation, the length of the workpiece decreases and its cross-section area increases.
In this process, a compressive force is applied a parallel direction to its length axis.
 Cogging :
 Drawing down is a process of elongate the length and reduce the cross section area of work piece.
 Simply in this operation, the length of the workpiece increases and the cross-section area decreases.
 In this process, a compressive force is applied in the perpendicular direction of its length axis.

Fullering:
 Fullering is a crucial step in the forging process.
 It involves creating a sharp transition in cross-sectional areas using only a hammer and the
edge of the anvil.

Edging :
 The function of edging is to distribute the metal longitudinally by moving metal from
the portion of the stock where it is in excess to the portion which is deficient in metal.
 Flattening :
 This operation is used to flatten the stock so that it fits properly into the finishing
impression of a close die.

Swaging :
 Swaging is a forging process that uses compressive forces to change the shape and size
of a metal workpiece. It can be done by forcing the material through a die.

Bending :
 It is the process of bending or shaping a metal rod or plate into a round or angular shape.

Blocking :
 It is a forging operation which imparts to the forging its general but not exact or final shape.
 This operation is done just prior to finishing operation.
 Forging Equipment and Tools
Hammers Anvils Dies
 Used to apply compressive force to the
 Sturdy metal blocks that provide a solid  Specially designed tools that shape
heated metal during the forging process.
surface for the forging operation. the metal into the desired form
during the forging process.
Presses Rolling Mills Furnaces
 Apply controlled, continuous force to  Gradually shape the metal by passing  Heat the metal to the appropriate
gradually shape the metal. it between rotating, grooved rolls. temperature for forging.
Applications of Forged Products
The forging process is widely used in manufacturing industries for producing large
numbers of the product like automotive, aerospace and industrial equipment.

Automotive
 Forged parts are used in engines, transmissions, and suspension systems,
providing strength and durability.

Aerospace
 Forged components are critical in aircraft and spacecraft, where weight,
strength, and reliability are paramount.

Industrial Equipment
 Forged parts are used in a wide range of industrial machinery, ensuring
reliable performance under demanding conditions.
Advantages and Disadvantages of Forging
Advantages:
• Forging gives comparatively tougher products compared to casting.
• The fatigue strength and creep resistance of forge products is higher.
• Forge product has higher mechanical properties.
• Low-cost operation.
• This process does not require a special skill operator.
• Variety of shapes can be formed by this process.

Disadvantages:
• Higher initial cost for big forging presses.
• Secondary finishing process required in hot forging.
• It cannot produce complex shapes.
• Size is limited due to the size of the press.
• Brittle metal cannot be forged.
 Defects in Forging:
1. Unfilled section or underfill :
 This type of forging defects left some portion unfilled.
Caused by :-
1. Poor design of die
2. Less raw material
3. Poor heating
Remedies:-Proper care must be taken on.
1.The die design
2.Heating
3. There should be enough raw material
2. Cold Shut:
 This type of forging defect occurs as small cracks at the corners of the object.
Caused by:-
1. Improper design of the forging die
2. Sharp corners of the object
3. Excessive chilling of the forged product
Remedies:-Proper care must be taken on
1. The fillet radius of the die is to be increased.
2. Working temperature should be maintained.
3. Scale pits:
 Scale pit is usual in forging carried out in an open environment,
it causes irregular deputations on the forging surfaces.
Caused by:-
1. This type of forging defect occurs due to improper cleaning of the forged surface.
Remedies: avoided by adequate cleaning of forged surface.
4. Die shift:
1.This forging defect is caused when the upper and lower dies are not aligned with each other,
this will lead to improper dimensions of the product.
Caused by :-
1. When dies are not aligned with each other.
Remedies:-
1. This defect can be avoided when the die is properly aligned.
2.It can be done by placing half portion of the workpiece on the upper die and
half on the lower die, so that both portion can match.
5.Flakes:
1. It is internal cracks caused when the forged products cool quickly, and it reduces the
strength of the forge product.
Caused by:-
1. This type of forging defect occurs due to improper cooling of the forged product.
Remedies:-
1. Flakes can be avoided when proper cooling is performed.
6.Surface Cracking :
1. This type of forging defects arises when the forging operation is performed
At low temperature which leads to occurrence of cracks on the workpieces.
Caused by :
1.Operating in low temperature.
Remedies :it can be controlled by working on a proper temperature.
 Heat Treatment of Forging :
After their manufacture ,forgings are heat treated before and after machining.
The initial treatment is done to improve the grain structure.

Annealing:
 Annealing is a form of treatment which is used to accomplish the following results:
remove internal stresses , improve mechanical properties , make the metal make the
metal softer for machining or grinding.

Hardness:
 Hardening heat treatments are used to enhance the hardness of the metal surface
through heating and rapidly cooling.

Tempering:
 It is the heat treatment process used in metallurgy to improve the mechanical
property of the treated material.

Normalising:
 Normalising is the heat treatment process that is used to make a metal more ductile
and tough.
 Lubricant Used in Forging:
 The lubricant is continuously exposed to changing pressures and velocities
and wear or pick up products in the lubricant also continuously vary,
although a dynamic equilibrium may be attained through careful control.
 The absence of steady-state conditions creates challenges for the systematic
analysis of lubrication and wear in forging processes.
Forging Temperature:
Conclusion

 Forging enhances metal strength, durability, and reliability through

its controlled deformation process, resulting in high-quality, resource-efficient parts.
While initial costs can be high, the process offers long-term benefits in performance
and material efficiency, making it suitable for a wide range of applications and
industries. Continuous advancements further improve its effectiveness and versatility.
 THANK
YOU…