Metal forging is the process in which metals are formed and shaped using compressive forces. The forces are delivered using hammering, pressing, or rolling.
There are a number of forging processes – cold forging, warm forging, and hot forging – which are classified by the temperature of the metal being worked with.
Forging is one of the more pivotal metalworking processes in the metal manufacturing industry. It’s especially vital in the iron and steel industries and is viewed as a tremendous source of productivity.
There are four primary tools that are used in the metal forging process depending on the exact method being used.
The hammer, or power hammer, is a tool most commonly associated with forging. Whether a hand-held hammer or a massive power hammer, the tool is used to repeatedly hit the metal in order to deform it. As long as it possesses a 50,000 lbs driving force to deliver high-pressure impact blows, a hammer can pound metal into shape.
Presses use either mechanical or hydraulic pressure to apply continuous pressure on forging dies. This kind of equipment requires a 50,000 ton driving force to vertically squeeze metal into die cavities with controlled high pressure. Instead of hitting the metal repeatedly to deform it, the metal is slowly pressed into the dies.
Upsetter forging is similar to press forging, however, the main difference is that an upsetter is a forging press that is used horizontally. Instead of forcing the metal downward into a die, the metal is moved into the die impression in a horizontal direction.
Ring rollers are used to produce rings with diameters from just a few inches to over 300 inches. Ring rollers squeeze out a one-piece ring, which removes the need for welding. It turns a hollow round piece of metal under extreme pressure against a rotating roll.