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Explain Forging with advantages.

Explain Forging with advantages.

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Forging :-

  • Forging is an oldest shaping process used for the producing small articles for which accuracy in size is not so important.

  • The parts are shaped by heating them in an open fire or hearth by the blacksmith and shaping them through applying compressive forces using hammers.

  • Thus forging is defined as the plastic deformation of metals at elevated temperatures into a predetermined size or shape using compressive forces exerted through some means of hand hammers, small power hammers, die, press or upsetting machine.

  • It consists essentially of changing or altering the shape and section of metal by hammering at a temperature of about 980°C, at which the metal is entirely plastic and can be easily deformed or shaped under pressure.

  • The shop in which the various forging operations are carried out is known as the smithy or smith’s shop. A metal such as steel can be shaped in a cold state but the application of heat lowers the yield point and makes permanent deformation easier.

  • Forging operation can be accomplished by hand or by a machine hammer. Forging processes may be classified into hot forging and cold forgings and each of them possesses their specific characteristics, merits, demerits and applications.



Advantages of forging :-

Some common advantages of forging are given as under.

  • Forged parts possess high ductility and offers great resistance to impact and fatigue loads.

  • Forging refines the structure of the metal.

  • It results in considerable saving in time, labor and material as compared to the production of similar item by cutting from a solid stock and then shaping it.

  • Forging distorts the previously created unidirectional fiber as created by rolling and increases the strength by setting the direction of grains.

  • Because of intense working, flaws are rarely found, so have good reliability.

  • The reasonable degree of accuracy may be obtained in forging operation.

  • The forged parts can be easily welded.



Disadvantages of forging :-

Few dis-advantages of forging are given as under.

  • Rapid oxidation in forging of metal surface at high temperature results in scaling which wears the dies.

  • The close tolerances in forging operations are difficult to maintain.

  • Forging is limited to simple shapes and has limitation for parts having undercuts etc.

  • Some materials are not readily worked by forging.

  • The initial cost of forging dies and the cost of their maintenance is high.

  • The metals gets cracked or distorted if worked below a specified temperature limit.

  • The maintenance cost of forging dies is also very high.



Applications of forging :-

  • Almost all metals and alloys can be forged. The low and medium carbon steels are readily hot forged without difficulty, but the high-carbon and alloy steels are more difficult to forge and require greater care.

  • Forging is generally carried out on carbon alloy steels, wrought iron, copper-base alloys, alumunium alloys, and magnesium alloys. Stainless steels, nickel?based super-alloys, and titanium are forged especially for aerospace uses.

  • Producing of crank shaft of alloy steel is a good example which is produced by forging.

  • Forging processes are among the most important manufacturing techniques utilized widely in manufacturing of small tools, rail-road equipments, automobiles and trucks and components of aeroplane industries.

  • These processes are also extensively used in the manufacturing of the parts of tractors, shipbuilding, cycle industries, railroad components, agricultural machinery etc.

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