Forging and its Benefits

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Forging and its Benefits
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What is Forging?

• Forging is a manufacturing process involving the
  shaping of metal using localized compressive
  forces.
• The blows are delivered with a hammer (often
  a power hammer) or a die.
• Forging is often classified according to the
  temperature at which it is performed
• Cold forging (a type of cold working)
• Warm forging or hot forging (a type of hot
  working).

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Why Forging and not Casting
Forged parts had a 26 higher tensile
strength than the cast parts. This means you can
have stronger shackles at a lower part
weight. Forged parts have a 37 higher fatigue
strength resulting in a factor of six longer
fatigue life. This means that a forged shackle is
going to last longer. Cast iron only has 66 of
the yield strength of forged steel. Yield
strength is an indicator of what load a shackle
will hold before starting to deform. The forged
parts had a 58 reduction in area when pulled to
failure. The cast parts only had a 6 reduction
in area. That means there would be much greater
deformation before failure in a forged part.
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What is Open Die Forging?
Open die forging is the process of deforming a
piece of metal between multiple dies that do not
completely enclose the material. The metal is
altered as the dies hammer or stamp the
material through a series of movements until the
desired shape is achieved. Products formed
through open forging often need secondary
machining and refining to achieve the tolerances
required for the finished specifications. Custom
shapes can also be produced with open die
forging. Some additional benefits of open die
forging include improved fatigue resistance and
strength. Open die forging also reduces voids.
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What is Rolled ring Forging
Rolled ring forging is used in a number of
sectors, from the nuclear industry to machine
shops to pharmaceutical companies. Rolled ring
forging is a process that begins with a circular
preform of metal that has already been pierced to
make a hollow doughnut shape. This ring is
heated, then rotate to reduce its wall thickness
and increasing the diameters of the resulting
ring.
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Industries Demanding Forge

• These industries include
• Power Generation
• Nuclear Power
• Gas Compression/Turbo-Machinery
• Petrochemical/ Oil and Gas
• Industrial Equipment Manufacturers
• Aerospace
• Military 

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What are the benefits of forging?
Greater strengthOnly  the forging process can
yield a grain structure oriented to the part
shape,  resulting in optimum  toughness, 
ductility, impact strength andfatigue
strength.Fewer defectsForgings are produced
from the cleanest steels thereby
minimizing non-metallic inclusions and retained
gases that are found in castings and
plate.Under the MicroscopeForgings have a much
more  uniform structure and finer grain size than
castings or plate resulting  in more predictable
and uniform mechanical properties as well as
higher  yield strengths for any given hardness
level. Conversely, localized  "soft spots" in
castings  plate can develop into cracks and
lamination respectively.
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Cont
Made to OrderForging is often the only 
metalworking process available with certain
grades in desired sizes.EconomicalOpen
die forging has no pattern or die  costs.
In addition, forgings are produced close to final
shape thereby  minimizing material waste. 
As material costs increase, forgings become a
cost effective alternative to the wasteful
process of flame cutting.ReliabilityWhen
reliability is critical, design  engineers will
often specify forgings. The combination of
strength,  ductility, uniformity, and cleanliness
is  unmatched by alternative  products.
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