Small forging operations can be completed by striking the material with a hammer, but heavier forging tasks are only completed by machines. There are three main techniques to forge. Typically, an iron-related job is referred to as blacksmithy.
Metal components frequently undergo four different forging processes. These techniques include seamless rolling ring forging, cold forging, open die forging, and impression die forging (closed die).
Metal forgings offer a highly effective approach to producing a variety of parts for all purposes by applying localized compressive stresses. In this reading, we’ll explore the various types of forging operations.
Let’s begin!
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Types of Forging Operations
The types of forging operations are upsetting, drawing, bending, fullering, edging, cutting, swagging, forge welding, punching, flating, setting down, and jumping.
1. Upsetting:
We perform these forging operations to expand the length of the workpiece by increasing its cross-sectional area. The force is applied in a parallel direction to the long axis. A good example of an upsetting operation is a bolt head.
This procedure was used to expand the stock’s cross-sectional area over the length extension. To achieve the length, for instance, in the development of the bolt head, the offsetting force is applied in a direction parallel to the long axis.
2. Drawing:
By pulling and stretching in the cross-sectional area, these types of forging operations lengthen the metal. We apply the force perpendicular to the length axis. To extend a metal’s length is called Drawing out.
The image below illustrates this process. The hammer strikes the beak of the anvil after heating the metal to a temperature between two and one. Fuller is also used for this purpose.
3. Bending:
“Bending” is the act of turning or bending a piece of metal into a round or angular shape. We use this process to create round rings and other shapes. Bending operation is the most common and easiest forging. It is done to give a turn shape to a metal rod or plate.
4. Fullering:
Fullering is a forging operation done by keeping the bottom fuller in an angle hole with the heated metal placed on it; the top fuller is then placed above the metal, and force is applied through the top fuller using a sledgehammer.
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5. Edging:
This forging operation is carried out by striking or forcing the metal plate into the desired shape. The workpiece is forced between two die edges.
6. Cutting:
Cutting is a forging operation that is carried out when metal needs to be cut apart. The operation is done when the metal is in a red-hot condition using a chisel and hammer.
It is the process of reducing the length of long metal rods and plates; it can be done with cold or hot metals and requires the use of a chisel with a cutting angle. Metals thicker than 20 mm should only be cut after being heated.
7. Swaging:
This forging operation is done to reduce the finished work into the desired size and shape, usually either round or hexagonal. Bottom swage is used for small jobs, while large jobs are performed by swage block.
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8. Forge welding:
These types of forging operations are performed when two pieces of metal need to be joined to increase the length. The operation is done by pressing or hammering the workpiece edge by edge while still adhered.
In this method, the metal pieces are heated at the proper temperature in a furnace and joined together by pressure or blows. The ends of the metal pieces are scarfed during forge welding by jumping.
9. Punching:
This forging operation is done to produce holes in the workpiece. The workpiece is placed on a hollow cylindrical die, placing the punch to the area where a hole is required.
In this procedure, a punch is used to create a hole in heated metal. The work is first placed on the punch hole of the anvil, nut, etc., for punching, after which the hole is either made with a punch or holes that have already been made by drift are widened.
10. Flattening and setting down:
Flatting and setting down are done to obtain a smooth surface with the use of a flatter or set hammer. This operation is done after fullering leaves a corrugated surface on the metal or after the workpiece is forged into shape with a hammer.
11. Jumping:
Jumping or upsetting refers to the process of heating metal in order to shorten and thicken it. The length of the metal can be almost cut in half by hopping. One can jump in three different ways: head jumping, center jumping, and full jumping.
Related: What is the Difference Between Casting and Forging?
