PRESENTATION ON FORGING FOR MECHANICAL STUDENTS

2. FORGING SHOP
Forging is a manufacturing process involving the shaping
of metal using localized compressive forces. Forging is
often classified according to the temperature at which it
is performed: "cold", "warm", or "hot" forging. Forged
parts can range in weight from less than a kilogram to 580
metric tons.Forged parts usually require further
processing to achieve a finished part.

3. TYPES OF FORGING
HOT FORGING: It is the controlled plastic deformation of metals at elevated
temperature by using the external pressure.
The pressure may be applied by hand hammers or power hammers .So in this
,pressure apllied is not continuous but intermittent.
Following are some of the examples of hot forging
1.HAMMER OR SMITH FORGING
2.DROP OR DIE FORGING
3.PRESS FORGING
4.UPSET FORGING
5.ROLL FORGING
6. SWAGGING
HOT FORGING

4. PRESS FORGING
PRESS FORGING
Press forging uses the impression dies but
plastic deformation of metal is done by a slow
squeezing action.
The presses used for press forging are:
Mechanical press (crank,electric,knuckle) and
hydraulic press.

5. Swaging
Swaging
In this process of hot forging
rods or tubes are reduced in
size by the repeated blows of
opposed .The repeated blows
cause the metal to flow inward
and take the shape of die

6. COLD FORGING
 Cold Forging is a cold working process where the material is squeezed into a
die and the finished parts assume the shape of the die. This process is also
known as Cold Heading.

7. Applications of forging
• The portion of work in which forging is done is termed as
forge and the work is mainly performed by
hammers,machines,and presses.
• Forging processes are among the most important
manufacturing techniques as it is used in small tools ,
automobile sector, as well as home and other accessories.

8. FORGING TOOLS AND
EQUIPMENTS
 1) TONGS : USED FOR HOLDING WORK EHILE DOING A FORGING WORK.
 2) HAMMER : USED FOR HAND FORGING.
 3) ANVIL : ACTS AS A SUPPORT FOR FORGING WORK.
 4) SWAGE BLOCK : USED FOR SIZING, SQARING AND BENDING.
 5) FURNACE : USED FOR IN HOT FORGING FOR HEATING THE METAL PIECE TO
RED HOT.

9. Advantages and disadvantages of
forging
ADVANTAGE DISADVANTAGES
 No weight loss. 1.High tool cost
 Smooth surface 2.High tool maintenance
 High speed of production 3.Limitation in size and shape

10. TYPICAL FORGING DEFECTS
 •Pitted surface, due to oxide scales occurring at high temperature stick on the dies.
 •Buckling, in upsetting forging. Subject to high compressive stress.
 •Microcracking, due to residual stress.

11. •Flash line crack, after trimming-occurs
more often in thin workpieces. Therefore
should increase the thickness of the flash.
•Cold shut or fold, due to flash or fin
from prior forging steps is forced into the
workpiece.

12. JOB OF FORGING SHOP
SCREW DRIVER BY HOT FORGING

13. TO PREPARE “S” HOOK BY
FORGING
1.Cut the required length of
metal piece with hacksaw
1.Then mark the required
dimensions on it
3.Heat the M.S. rod in coke fired
furnace till red hot
temperature .Re0move the job
from furnace and make the
required shape
And size of the job piece on one