FORGING DEFINED
Forging is defined as the process of heating, deforming, and finishing a piece of metal. Forgings are made by forcing materials into customized shapes either by the force of a falling ram upon an anvil or by a die press enclosing a piece of metal and squeeze-forming the part. Due to the realigning of the grains of metal when heated and deformed, forgings can withstand extreme pressure and maintain structural integrity under stress. Once produced, forgings have a broad range of uses across a variety of industries ranging from heavy trucks, medical supplies, automotive parts, to aerospace.
What is The Metal Forging Process?
When choosing a type of forging, buyers have a long list of options for producing a critical metal component. It can be challenging to make the right choice, because each technique comes with varying pros and cons, revolving around costs and logistics.
However, choosing the forging method brings a plethora of unique benefits unavailable with any other choice.
With regards to price and overall quality, metal forging brings the most value. This notion rings doubly when maximum part strength, custom sizes, and critical performance specifications are needed for the application.
Benefits of Forging
The many positive features of forging is the reason that it has been a central part of metal forming for so many years. Machinery, engines, and technical equipment depend on forging to supply strong, lasting, and reliable parts that provide optimum performance in any conditions. Manufacturers and producers depend on forging to provide the components for their products due to the positive and beneficial performance of forged parts.
Directional Strength
The controlled deformation of the forging process results in metallurgical soundness and exceptional mechanical properties. This factor is the result of the pre-working of the metal before inserting it in the forging process, which creates the proper grain flow and directional properties of strength, ductility, and resistance to impact and fatigue.
Resistance to Fatigue
Other metal fabricating methods cut the grain flow lines exposing ends, which leads to fatigue and sensitivity to corrosion. The forging process maintains the grain flow such that it follows the contour and shape of the component or part. By maintaining the grain flow, forged parts have greater fatigue and corrosion resistance.
Flexibility of Design
As engineers and designers work on their conceptualizations, they are able to create parts with greater strength due to an understanding of how forging affects the grain flow and makes designs resistant to fatigue and failure. Forging allows designers to choose the correct materials and heat treatments for each component, which results in improved mechanical strength, resilience, and impact resistance.
Varying Thicknesses
The forging process allows for parts to have varying thicknesses due to the higher strength to weight ratio. The ability to mass produce parts using one operation capable of varying thicknesses saves time, production costs, and shortens manufacturing runs. Regardless of the material, there is consistency of the flow of the material from one forging to the next.
Custom Designs
Custom forgings are produced swiftly and economically using a wide variety of materials and design requirements in a broad range of sizes. With the many innovations used by forging companies, custom designs are quickly produced economically and efficiently. Unusual shapes and configurations have become more feasible and are produced with improved precision.
Strength
The primary benefit of forging is the strength it provides for completed products. This is the result of the metal being able to retain its grain structure and alignment during the forging process. Preprocessing and pre-working of the metals removes any concerns for contaminants that could damage or harm a component‘s strength. During recrystallization, metals solidify flawlessly since potential harmful contaminants have already been removed.
Production Rates
A major benefit to the auto industry is the high production rates of forging. Metals enter the forging process, and parts leave rapidly and efficiently in a matter of seconds in the cold forging process. In the hot forging process, the time increases to minutes with the delay for heating metals. Regardless of the part, the forging process can be seamless and economically integrated into pre-existing manufacturing operations.
Finishing
Though some forged parts may require after production finishing, the majority leave the forging process with completed finishes and flawless surfaces. This aspect of the process is another reason for the increase in production efficiency.
Downtime
The lack of complexity in the forging process leads to less downtime and fewer rejected or poor quality parts. In modern business, this is an important factor in order fulfillment and lower production costs.
Waste
Of the problems related to metal production, waste is one of the most costly and damaging. A major benefit of forging is the absence of waste. Any metal that is left from the forging process can be repurposed and recycled. In most manufacturing processes, the handling of scrap and waste is a significant labor and time cost. With forging, those costs are eliminated, and the focus is on production.
Metal Materials of Forging
Much of the determination of which forging process to use is dependent on the type of metal. Nearly every metal can be forged regardless of the fact that metals have different characteristics and properties in relation to their weight, tensile strength, and deformation capabilities.
The common types of metals for forging include carbon, alloy, stainless steel, aluminum, titanium, brass, copper, cobalt, nickel, and molybdenum.
Forged products can be structural components in the following:
Critical aircraft parts:
Transportation equipment:
Also, forging is used to fortify hand tools (e.g., chisels, rivets, screws, and bolts).
Xiange adds value to our client's businesses by exploring ways to deliver your parts at a lower cost-per-part to help you drive your profitability and business margins.
Cost and Profitability
High quality
Xiange uses experience and capacity to bring you the best die-casted parts. We take every step seriously before delivery, and run every production process, from raw material sourcing to finishing, through our quality control systems.
Shorter lead times
Xiange will optimize our pressure die casting services to help you get to your target audience quicker. Our in-house capacity also helps us make tooling faster, shorten casting cycles, and land products quicker.
Xiange can handle your entire product development cycles from design to prototypes and the final part. Our one-stop-shop services also cover your product development from raw material screening to casting and finishing solutions that enhance your parts' appearance and functionality.
One-stop shop
Recieve a Custom Quote
Need a precision engineered component? Click below to receive a rapid quote from our team.