Forging - 2

Processes
There are many different kinds of forging processes available;

however, they can be grouped into three main classes:[1]
Drawn out: length increases, cross-section decreases

Upset: length decreases, cross-section increases
Squeezed in closed compression dies: produces multidirectional
flow
Common forging processes include: roll forging, swaging, cogging,
open-die forging, impression-die forging (closed die forging), press
forging, cold forging, automatic hot forging and upsetting.[1][4]
Temperature
All of the following forging processes can be performed at various
temperatures; however, they are generally classified by whether the
metal temperature is above or below the recrystallization A cross-section of a forged
temperature.[5] If the temperature is above the material's connecting rod that has
recrystallization temperature it is deemed hot forging; if the been etched to show the
temperature is below the material's recrystallization temperature but grain flow
above 30% of the recrystallization temperature (on an absolute scale)
it is deemed warm forging; if below 30% of the recrystallization
temperature (usually room temperature) then it is deemed cold forging. The main advantage of
hot forging is that it can be done more quickly and precisely, and as the metal is deformed work
hardening effects are negated by the recrystallization process. Cold forging typically results in work
hardening of the piece.[6][7]
Drop forging
Drop forging is a forging process where a hammer is raised and
then "dropped" into the workpiece to deform it according to the
shape of the die. There are two types of drop forging: open-die
drop forging and impression-die (or closed-die) drop forging.
As the names imply, the difference is in the shape of the die,
with the former not fully enclosing the workpiece, while the
1:03 latter does.
Boat nail production in Hainan, Open-die drop forging

China
Open-die forging is also known as smith forging.[8] In open-die
forging, a hammer strikes and deforms the workpiece, which is
placed on a stationary anvil. Open-die forging gets its name from the fact that the dies (the surfaces
that are in contact with the workpiece) do not enclose the workpiece, allowing it to flow except
Forging 2
where contacted by the dies. The operator therefore needs to orient
and position the workpiece to get the desired shape. The dies are
usually flat in shape, but some have a specially shaped surface for
specialized operations. For example, a die may have a round, concave,
or convex surface or be a tool to form holes or be a cut-off tool.[9]
Open-die forgings can be worked into shapes which include discs,
hubs, blocks, shafts (including step shafts or with flanges), sleeves,
cylinders, flats, hexes, rounds, plate, and some custom shapes.[10]
Open-die forging lends itself to short runs and is appropriate for art
smithing and custom work. In some cases, open-die forging may be
employed to rough-shape ingots to prepare them for subsequent
operations. Open-die forging may also orient the grain to increase Open-die drop forging (with
strength in the required direction.[9] two dies) of an ingot to be
further processed into a
wheel
Advantages of open-die forging
Reduced chance of voids

Better fatigue resistance
Improved microstructure
Continuous grain flow
Finer grain size
Greater strength[11]
Better response to thermal treatment[12]
Improvement of internal quality
Greater reliability of mechanical properties, ductility and
impact resistance
"Cogging" is the successive deformation of a bar along its
length using an open-die drop forge. It is commonly used to
work a piece of raw material to the proper thickness. Once the
proper thickness is achieved the proper width is achieved via
"edging".[13] "Edging" is the process of concentrating material A large 80 ton cylinder of hot steel in
using a concave shaped open-die. The process is called "edging" an open-die forging press, ready for
because it is usually carried out on the ends of the workpiece. the upsetting phase of forging
"Fullering" is a similar process that thins out sections of the
forging using a convex shaped die. These processes prepare the
workpieces for further forging processes.[14]
Forging 3

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Processes

There are many different kinds of forging processes available;

Drawn out: length increases, cross-section decreases

Boat nail production in Hainan, Open-die drop forging

Reduced chance of voids

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