Forging

Forging machine

Boating hook made by forging

Counterweight made by forging

Forging is a metal shaping process in which a heated work piece is formed by rapid closing of a punch and die forcing the work piece to conform to a die cavity. In forging, a work piece may be made by a series of punch and die operations to gradually change its shape. Flash at the seam of the punch and die acts as a relief valve for the extreme pressure produced by the closing die halves. Flashing is removed after forming.

Forging offers low cost for moderate to long runs and can produce a wide variety of 3D shapes, usually without side holes or recesses. Examples of parts made by forging include connecting rods, crankshafts, wrenches, hooks etc. Forging can process metals with good ductility such as aluminum, copper, nickel, mild steel, stainless steel, magnesium, etc. Custom steel tooling is required for forging. Cost optimization options include minimizing size of workpiece and reducing shape complexity.

Forging Design Considerations

• Walls must have draft - approx 6 deg is recommended.
• Recommended internal draft - approx 8-10 degrees is recommended.
  
• Shape must allow ejection from tooling.
• Provide generous fillet and corner radii to aid material flow.
  
• Produces a parting line on the work piece.
  
• May require secondary machining to obtain dimensional tolerances and good surface finish.