Forging

What Is forging?

Forging, a metal shaping technique using compressive, localized forces, has been a staple metal fabrication technique since the time of the ancient Mesopotamians. Since its origins in the fertile crescent, forging has experienced significant changes, resulting in a more efficient, faster, and more durable process. This is because today, forging is most commonly performed with the use of forging presses or hammering tools that are powered by electricity, hydraulics or compressed air. Some of the common materials used for forging are carbon steel, alloy steel, microalloy steel, stainless steel, aluminum, and titanium.

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What is the purpose of forging?

The purpose of forging is to create metal parts. Compared to other manufacturing methods, metal forging produces some of the sturdiest manufactured parts available. As metal is heated and pressed, minor cracks are sealed, and any empty spaces in the metal close.

The hot forging process also breaks up impurities in the metal and redistributes such material across the metalwork. This vastly reduces inclusions in the forged part. Inclusions are compound materials implanted inside steel throughout manufacturing that cause stress points in the final forged parts.

While impurities should be managed during the initial casting process, forging further refines the metal.

Our forging product

The pounding action of forging deforms and shapes the metal, which results in unbroken grain flow. This causes the metal to retain its strength. Ancillary effects of this unique grain flow include the elimination of defects, inclusions, and porosity in the product. Another advantage of forging is the relatively low costs associated with moderate and long production runs. Once the forging tools have been created, products can be manufactured at relatively high speeds with minimal downtime.There are two main types of forging: hot and cold.

Rolled Ring Forging

Close Die Forging

Open Die Forging

Fully Machined Component

rolled ring forging

CM TECHNO WEB has advanced capabilities for the manufacture of ring rolled forging.

Our ability to optimize manufacturing and process capabilities, while offering the “insurance” back-up of 6 ring mills, allows us to deliver the highest quality ring to you in the least amount of time.

Rectangular or profile rings as per customer’s requirement.

Rings are made from Carbon Steel, Alloy Steel, Structural & Tool Steel, Low Carbon Steel & Stainless Steel.

Close Die Forging

CLOSED DIE FORGING is the process whereby this deformation is confined within a shaped cavity in the dies to achieve a desired engineering configuration. Depending on such factors as complexity, tolerances, economics and performance, the dies required to produce Closed Die forgings range from complex multi-segmented PRECISION wrap dies to simple two-piece CONVENTIONAL top-and-bottom dies.

Cm Techno Web supplied below industries.

1.Automotive
Bearing Races, General Engineering Product, Hub, Differential Case and Cover and Transmission parts

2. Material Handling / Construction / Earth Moving
Gears, Rollers, Idlers, Crane Wheels,

3.Railways
Traction Gears and Bearing Shells

4.Oil And Gas
Metal Gasket, Valve Bodies, Gates, Flanges, Discs for Valves and Forged Fittings

Open Die Forging

OPEN DIE FORGING involves the shaping of heated metal parts between a top die attached to a ram and a bottom die attached to a hammer anvil or press bed. Metal parts are worked above their recrystallization temperatures-ranging from 1050°C to 1250°C for steel-and gradually shaped into the desired configuration through the skilful hammering or pressing of the work piece.

While impression or closed die forging confines the metal in dies, open die forging is distinguished by the fact that the metal is never completely confined or restrained in the dies. Most open die forgings are produced on flat dies. However, round swaging dies, V-dies, mandrels, pins and loose tools are also used depending on the desired part configuration and its size.

Although the open die forging process is often associated with larger, simpler-shaped parts such as bars, blanks, rings, hollows or spindles, in fact it can be considered the ultimate option in “custom-designed” metal components. High-strength, long-life parts optimized in terms of both mechanical properties and structural integrity are today produced in sizes that range from a few pounds to hundreds of tons in weight. In addition, advanced forge shops now offer shapes that were never before thought capable of being produced by the open die forging process.

Fully Machined Component

At Cm Techno Web we offer a full range of in-house machining options to take your forgings to near-finished dimensions.

A combination of over 26 CNC machine & 4 VMC Machine gives us the ability to turn, mill, or bore your parts as specified, with finishes ranging from 500 to 16 RMS.

For CNC Machine Capacity Up-to 100 Kg. Single Pc.
For VMC Machine Capacity Up-to 100 Kg. Single Pc

Cm Techno Web supplied in below industries with fully machined component :

Automotive Parts
Transmission Gears & shaft
Hubs & Sleeves
Bearing Races
Valve Body
Pump Parts
Railway Bearings & hubs
And many more as per customer’s requirement.

What are the different forging processes?

Beyond basic hot and cold forging, many specific processes exist. This broad range of processes can be grouped into three primary umbrella groups: Draw forming decreases the width of the product and increases length. Upset forging increases the width of the products and decreases length. Compression forming provides forging flow in multiple or customized directions.These three categories entail many different specific types of metal forging methods.

Drop Forging Process

Drop forging gets its name from the process of dropping a hammer onto the metal to mold it into the shape of the die. The die is the surface that comes into contact with the metal. There are two types of drop forging: open-die and closed-die forging. Dies are typically flat in shape with some having distinctively shaped surfaces for specialized operations.

Press Forging Process

In press forging, the main forming factor is compression. The metal sits on a stationary die while a compression die applies continuous pressure, achieving the desired shape. The metal’s contact time with the dies is considerably longer than other types of forging, but the forging process benefits from being able to simultaneously deform the entire product, as opposed to a localized section. Another benefit of press forging is the ability of the manufacturer to monitor and control the specific compression rate. Applications of press forging are numerous, as there are relatively no limits to the size of product that can be created. Press forging can be hot or cold forged.

Roll Forging Process

Roll forging is the process of increasing rods or wires in length. The manufacturer places heated metal bars between two cylindrical rolls with grooves, which rotate and apply progressive pressure to shape the metal. The precisely shaped geometry of these grooves forges the metal part to the desired shape. The benefits of this forging method include the elimination of flashing and a favorable grain structure. While roll forging uses rolls to produce parts and components, it is still considered a metal forging process and not a rolling process. Roll forging is frequently used to make parts for the automotive industry. It is also used to forge things like knives and hand tools.

Upset Forging Process

Upset forging is a forging process that increases the diameter of the metal through compression. Crank presses, a particular high-speed machine, are used in upset forging processes. Crank presses are characteristically set on a horizontal plane to improve efficiency and the quick metal exchange from one station to the next. Vertical crank presses or hydraulic presses are also used. The advantages of this process are that it enables a high production rate of up to 4500 parts per hour and full automation is possible. It also produces little to no waste.

Isothermal Forging Process

Isothermal forging is a forging process where the materials and the die are heated to the same temperature. The name comes from “iso” which means “equal.” This forging method is commonly used for forging aluminium, which has a lower forging temperature than other metals such as steel. Forging temperatures for aluminum are around 430 °C, while steels and super alloys can be 930 to 1,260 °C. The benefits are the near net shapes lead to lower machining requirements and, therefore, lower scrap rates, and the metal part is highly reproducible. Another advantage is that smaller machines can be used to make the forging due to the lower heat loss. A few disadvantages are the higher die material costs to handle temperatures and pressures and the required uniform heating systems. It also has a low production rate.