Which are the most common Forging Methods used in India?

There are numerous forging methods to choose from, each with its own set of benefits as well as capabilities. Two of the most common forging procedures are drop forging and roll forging.

Drop forging:

The act of striking metal with a hammer to mould it into the shape of the die is known as drop forging. The die refers to the surfaces that come into touch with the metal. Drop forging is divided into two types: open-die and closed-die. Although most die surfaces are smooth, some have specially tailored surfaces for specialised tasks.

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Open-die forging:

Open-die forging is also known as smith forging. A hammer smashes and deforms a metal on a stationary anvil. In this type of forging, the metal is never completely contained in the dies, allowing it to flow except when it comes into contact with the dies. Open-die forging is appropriate for simple and big parts, as well as customised metal components.

Closed-die forging:

The metal is pounded against an anvil after being pushed into a die. A hammer is used to strike the metal, causing it to flow and fill the die cavities. The hammer is timed to create many contact places with the metal on a millisecond scale. The flash outlasts the metal in the die because it cools faster than the rest of the substance. After forging, the flash is retrieved.

Roll forging:

In roll forging, semi-cylindrical horizontal rolls distort a round or flat bar stock. Its thickness is reduced while its length is increased. This heated bar is placed by rolling between two rolls having more formed grooves and is gradually shaped during the process. This step is repeated until the desired form and size are achieved.

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Press forging:

Press forging uses constant pressure instead of a drop impact used in the drop-hammer forging method. The deformation happens at a deeper depth, affecting the entire volume of the metal, due to the slower ram movement. Drop-hammer forging, on the other hand, simply deforms the metal's surface, leaving the interior comparatively unscathed. Internal strain in press forging can be controlled by varying the compression rate.

Upset forging:

Upset forging is a process that compresses the length of metal in order to increase its diameter. Crank presses, a type of high-speed machine, are employed in upset forging. To boost production and allow for faster metal exchange between stations, crank presses are frequently mounted on a horizontal plane. Hydraulic presses and vertical crank presses are also available.

Automatic hot forging:

In automatic hot forging, mill-length steel bars are inserted at room temperature into one end of the forging system, and hot forged objects will appear from the other end. The bar is descaled and separated into blanks with the help of rollers. Following that, the metal is sent through a variety of forming processes, some of which can be combined with high-speed cold-forming procedures. Typically, the cold-forming procedure is outsourced to the finishing stage.

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Precision forging:

Precision forging only demands a minimal amount of final machining. It's a forging technology that aims to cut the cost and waste associated with post-forging procedures. Cost savings occur from the reduction of material and resources, as well as the decrease in machining.

Isothermal forging:

Isothermal forging is a method of forging in which both the metal and the die are heated to the same temperature. Because the apparatus and the outside world have no net mass or thermal exchange, adiabatic heating is used. Internal alterations have resulted in highly regulated strain rates, causing the shifts.

Using compressive forces, metal forging is a method of forming and shaping metals to meet specific requirements. Pressing, Rolling or Hammering are used as force.