FORGING

1. SRIDHER REDDY
FORGING

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Introduction of FORGING •Forging is one of the metal forming process
•The oldest of the metalworking arts (primitive
blacksmith).
•Forging is the working of metal into a useful
shape by hammering or pressing.
The forging process can create parts that are stron ger than 
those manufactured by any other metalworking process. This 
is why forgings are almost always used where reliab ility and 
human safety are critical. 
•Forging machines are now capable of making
parts ranging in size of a bolt to a turbine
rotor.
•Most forging operations are carried out hot,
although certain metals may be cold-forged.

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Heating the material above re-crystallization 
temperature

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Why forging only

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FORGIN GRAIN FLOW of stub axel
Optimizing grain flow 
orientation maximizes 
mechanical properties.

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Forging Applications
(Chasses parts and engine parts) Crank shaft, connectin g rod, cam shaft, steering arms, stub axils, valves,  gear 
shift fork, differential casings, etc.

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SJust about any metal can be forged. However, some o f the most common metals
include: carbon, alloy and stainless steels; very h ard tool steels; aluminum; titanium;
brass and copper; and high-temperature alloys which contain cobalt, nickel or
molybdenum. Each metal has distinct strength or wei ght characteristics that best apply
to specific parts as determined by the customer.
STemperature may vary from metal to metal and depend ing on chemical compositions
SWhat metals are forged?

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Types of FORGING

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OPEN DIE FORGING
• Open-die forging is carried out between flat dies  or dies of
very simple shape no precut profiles .
(LARGER OBJECTS AND SMALL PRODUCTION)

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CLOSED OR IMPRESSION DIE STEEL FORGING
The work piece is deformed between two die halves ( called tooling) which
carry the impressions of the desired final shape.
•The work piece is deformed under high pressure in a closed cavity. •Normally used for smaller components. •The process provide precision forging
with close dimensional tolerance.
•Closed dies are expensive.
The grain flow of the metal can be controlled
Ensuring high mechanical properties.
Forging of complicated shapes can be made
Forging s are made with smaller machining
allowances

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M/C Allowance
IN FORGING WE CAN NOT GET THE FINISHED PRODUCT  
Before design the forge part should consider, all allowan ces blow shown
Shrinkage allowance
1.1% to 1.6%

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Raw material inspection
Raw material cutting
Band saw/shearing M/C
Raw material heating
Induction heating/oiled fire Furness
1100-1200 centigrade
Forging 
(2000T)
Pre-shaped (flattening)
Blocker (rough shape)
Finisher
Trimming
(150T)
Linishing /Grinding
To remove excess flash
Heat treatment
Hardening and Tempering
Normalizing, Stress reliving
Hardness testing
BHN test M/C
Coining
Magnaflux checking
(Crack free forging)
Demagnetizing
Final inspection
Rust prevention
(DWX-32 oil)
Packing & dispatch
Closed die Forging Process flow chart
Shot blasting

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FORGING RAW MATERIAL
SCS
RCS
ROUND 
BARSS

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BAND SAW M/C
Sawing Machines Sawing Machines Swaging is used to produce a bar/Rod with a smaller  pieces 
Advantages is good 
dimensional accuracy
Disadvantage blade 
will be cost, slow 
production

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FORGING BILLETS CUTTING
SHEARING M/C
Disadvantage is high 
force required, more 
tolerance required, 
shearing face will be 
taper and chance to 
break the material 
WHILE UPSETTING 
LAPS MY ACCURE
Advantages is fast 
production

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BILLETS  INSIDE OIL FIRED FURNESS
FURNESS OILE CONSIST  OF SULFER CONTENT 
DUE TO THIS OXIDIZATION WILL BE MORE 
AND SCALING WILL BE MORE
TO AVIDE OXIDIZATION ADDING NITROGEN 
OR NION

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1000 KW
INDUCTION FURNESS

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FORGE SHOP FORGE SHOP
Mechanical press —A forging press with an inertia 
flywheel, a crank and clutch, or other mechanical d evice to 
operate the ram. 

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BOLSTER PLATES
Bolster plate — A plate to which dies can be fastene d; the assembly is secured to the top surface of a  press bed. In 
press forging, such a plate may also be attached to  the ram.
Movable bolster fitted in to
the top of the m/c bed
Fixed bolster fitted in to
the bottom of the m/c bed
Bottom dies
Top dies

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DIES
FLATTENING 
dies (pre-shape)
Finisher die
Blocker die
Trim die
Fixed to the top 
bolster

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Parting Surfaces
The plane that 
divides the two 
forging die 
halves 

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FORGING PRESS

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EDGING BLACKER FINISHER OPERATIONS

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Lubrication Purposes
• Reduce friction
•Reduce die wear
•Thermally insulate part
•Remove scales from the die
•Die cooling

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BEFORE TRIMING
Flash: excess metal that extends out from the body  of the forging
to ensure complete filling of the finishing impress ions.
•Acts as a ‘safety value’for excess metal.

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TRIMING TOOL

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AFTER TRIMING
FLASH

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FORGED COMPONENT AFTER TRIM OPERATION

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FLASH SCRAP

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FORGING PRE OPERATION SHAPES
Billet
Pre-operations 
(flattening)

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Pre-shape
Blocker 
(semi finish)
Finisher 
with flash 

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Heat Treatment Heat Treatment

Continuous H & T Furnaces with Continuous H & T Furnaces with Water/Polymer/Oil Quenching Water/Polymer/Oil Quenching

Batch Furnaces for Normalizing / Batch Furnaces for Normalizing /
Stress relieving Stress relieving

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Heat Treatment Heat Treatment

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BHN Testing M/C BHN Testing M/C

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Shot Blasting Shot Blasting
Definition: Shot blasting consists of attacking the surface of a
material with one of many types of shots. Normally this is done
to remove something on the surface such as scale, b ut it is also
done sometimes to impart a particular surface to th e object
being shot blasted, such as the rolls used to make a 2D finish.
The shot can be sand, small steel balls of various diameters,
granules of silicon carbide, etc. The device that t hrows the shot
is either a large air gun or spinning paddles which hurl the
shot off their blades.

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Shot Blasting M/C swing table Shot Blasting M/C swing table

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GRINDING m/c

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Coining Coining
It is post-forging 
process -on hot or cold 
parts -to attain closer 
tolerances or improved 
surfaces.

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Crack Testing Crack Testing
––
(Magnaflux Checking ) (Magnaflux Checking )
AFTER MAGNAFLUX CHECK 
DEMAGNATISING WILL BE 
MUST

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Advantages and disadvantages Reduced machining time
Improve the physical properties of the starting met al Porosity in metal is largely eliminated
Impurities (inclusions) are broken up and distribut ed through the metal
Course grains are refined
Due to grain refinement, the physical properties ar e generally improved
»
Ductility and resistance

High working temp. can result in rapid oxidation/sc aling of surface = poor
surface finish

Generally, close tolerances are hard to control

Equipment and tool maintenance costs are high
»
Usually not used for short production runs
»
Die life is less

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DIE SHOP DIE SHOP

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DIE SHOP DIE SHOP

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MMT EDM Machine
DIE SHOP DIE SHOP

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CAD MODEL CRANKSHAFT TOP DIE

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CNC MEACHINES

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CNC DIE CUTTING (RE-CUTTING AFTER 
PRODUCTION)

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CNC DIE CUTTING

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FORGING PRODUCTS FORGING PRODUCTS

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CONNECTING ROD CONNECTING ROD
CRANK SHAFT CRANK SHAFT

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CENTER LINK
DIFFERENTIAL COVER

51. THANK YOU SRIDHER REDDY