What is Forging?

Types and their

Benefits
Forging is a manufacturing process where metal is modeled by applying pressure
after making it ductile through the application of heat. Forging techniques are useful
for working metal because they enable the desired shape to be given to the steel
and also improve its structure, especially because they refine its grain size.

Types of Forging
1. Hot Forging Forging process carried at a temperature above the
recrystallization temperature of the metal is called hot forging. This process is done
to prevent strain hardening during deformation

2. Cold Forging Forging process carried at a temperature below the

recrystallization temperature of the metal is called cold forging. This is done for
simple shaped components preferably softer metals/alloys. Compared to cold
forging, components produced by hot forging type are more ductile.

3. Press Forging In press forging, a continuous pressure or force is applied, unlike

the near-instantaneous impact of drop-hammer forging. In press forging,
deformation of complete work-piece occurs while in drop-hammer forging, usually
only the surfaces of the work piece in contact with the hammer and anvil deform;
the interior of the work-piece remain relatively undeformed.

4. Drop Hammer Forging It is a forging process where a hammer is lifted and

then dropped onto the work-piece to deform it according to the die-shape.

There are two types of drop forging

a. open-die drop forging and

b. closed-die drop forging

In Open-die forging, the work-piece is not fully enclosed while in Close-die forging,
the work-piece is fully enclosed.

Benefits of Forgings
In Casting, molten metal is poured into a mold to produce a component of desired
shape and allowed to solidify. This solidified part which is also called casting is
ejected/broken out of the mold, thus completing the casting process.
Forged steel is usually stronger and more reliable than castings since forging
involves alteration of the grain flow imitating the shape of the part. The thermal
cycle and deformation process leads to grain refinement and recrystallization which
eventually strengthens the resulting steel product.

Why are forged steel products better than castings?

1. Forged steel products are tougher than castings.

2. Forged steel has higher impact strength than castings

3. Forging eliminates the occurrence of shrinkage, porosity, cavities which are

usually encountered in castings.

4. High strength is attained by the tight grain structure of forgings. Thereby,

reducing need for expensive alloys to achieve high strength components.

5. The grain structure of forged components offers high wear resistance.

For more information visit www.kkmetals.com