Forging
Forging is a metal shaping process in which a heated work piece is formed
by rapid closing of a punch and a die forcing the work piece to conform to a die cavity.
A work piece may be forged by a series of punch and die operations (or by
several cavities in the same die) to gradually change its shape.
The hot metal to be shaped is placed on a die. Impact of a ram on the
work piece compels the hot and malleable metal to conform to the shape of a punch and die
cavity. 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.
Possible shapes
A wide variety of 3D shapes, usually without side holes or recesses.
Forging Design Guidelines
Avoid undercuts.
Recommended external draft: 6 degrees (96).
Recommended internal draft: 8-10 degrees (98-100).
Provide generous fillet and corner radii to aid material flow.
Provide support webs and ribs.
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Example parts
Connecting rods, crankshafts, wrenches, hooks etc.
Advantages of Forging
Low cost for moderate to long runs.
Specifications for Forging
 Material - Metals
with good ductility: aluminum, copper, nickel, mild steel, stainless steel, magnesium.
Alternative machines
- Mill 3-Axis, Casting.
Tooling - custom tooling
in the shape of the part.
Reducing costs - Minimize size, complexity and material volume.
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Notes
Produces a parting line on the work piece - location
where the lower and upper die (punch and die) meet. May require machining to
obtain dimensional tolerances and good surface finish.
Processes: Turning
Milling
Laser Cutting
Water Jet Cutting
Wire EDM
Tapping
Bending
Turret Punching
Fine Blanking
Blanking
Steel Rule Die Cutting
Drawing
Injection Molding
Extrusion
Metal Casting
Thermoforming
Forging
Springs
Wire forming
Powder Coating
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