Forging is a metalworking process that uses localized compressive forces to shape metal. It can be done cold or hot, with the metal heated in a forge for the latter two. Forged parts range in weight from less than a kilogram to hundreds of metric tons. Basic tools used in forging include furnaces, hammers, anvils, tongs, punches, and dies. There are several types of forging including impression die forging, cold forging, and open die forging. Impression die forging uses dies to restrict metal flow into a desired shape, allowing complex geometries. Cold forging is done without heating and includes processes like bending, drawing, and heading.

1. Assignment on:
Forging
Course Code: ME-3302
Course Name: Engineering Materials and Practices Lab
Submitted To:
Md. Nafeez Tanim
Lecturer,
Department of Textile
Engineering
Northern University
Bangladesh
Submitted By:
Mehedi Hasan
ID:BTX 130100279
Semester:Summer-2015
Dept. of Textile Engineering
Northern University
Bangladesh
Date of Submission:09.06.2015

2. Forging
Forging is a manufacturing process involving the shaping of metal using localized
compressive forces. The blows are delivered with a hammer (often a power hammer) or a die.
Forging is often classified according to the temperature at which it is performed: cold forging (a
type of cold working), warm forging, or hot forging (a type of hot working). For the latter two,
the metal is heated, usually in a forge. Forged parts can range in weight from less than a
kilogram to hundreds of metric tons.[1][2] Forging has been done by smiths for millennia; the
traditional products were kitchenware, hardware, hand tools, edged weapons, and jewellery.
Since the Industrial Revolution, forged parts are widely used in mechanisms and machines
wherever a component requires high strength; such forgings usually require further processing
(such as machining) to achieve a finished part. Today, forging is a major worldwide industry.
History of Forging
Forging is one of the oldest known metalworking processes. Traditionally, forging was
performed by a smith using hammer and anvil, though introducing water power to the production
and working of iron in the 12th century drove the hammer and anvil into obsolescence. The
smithy or forge has evolved over centuries to become a facility with engineered processes,
production equipment, tooling, raw materials and products to meet the demands of modern
industry.
In modern times, industrial forging is done either with presses or with hammers powered by
compressed air, electricity, hydraulics or steam. These hammers may have reciprocating weights
in the thousands of pounds. Smaller power hammers, 500 lb (230 kg) or less reciprocating
weight, and hydraulic presses are common in art smithies as well. Some steam hammers remain
in use, but they became obsolete with the availability of the other, more convenient, power
Different types of forging tools:
1. Furnaceor hearth: A black
smith uses a furnace for heating
the metal pieces. Furnace consists
of four legs, a cast iron or steel
body, iron bottom, a chimney and
a blower. The main parts of
forging furnace are as:

3. a. HEARTH: The iron bottom where fire is lightened is known as hearth. It is provided
with fire brick lining.
b. TUYERE: A pipe containing from the bottom or rear of the hearth is known as
tuyere. It is used to supply the air at high pressure.
c. HOOD: The upper part of furnace is called hood. It is made up of mild steel sheet
with the fire brick inside it.
d. CHIMNEY: Chimney is fitted on the upper end of the hood. It is used for the
purpose of easy escaping of exhaust gases and smoke.
e. WATER TANK: A small iron tank is attached with the hearth of the furnace. It is
used for dipping purposes
EQUIPMENT USED IN FORGIN
Shovel Blower Poker Regulator
1. Shovel: It is used to place the coal into the furnace hearth.
2. Blower:It is used to supply air at high pressure tothe hearth.
3. Poker:It is a bent rod used to strike the fire. Poker is made up of mild steel.
4. Regulator: It is used to control the air supply of air to the hearth. Air supply is
controlled by increasing or decreasing the passage of air.
5. Anvil: A block on which forging
work is done is known as anvil. It
is made up of cast iron, steel or
wrought iron. It acts as a
supporting device for all forging
operations since it is capable of
withstanding very heavy blows.
The anvil is supported either on a
iron base, or wooden block or
mounted on the foundation.
Weight of the anvil varies from
100-150Kg. It is available in
many sizes and shapes.

4. 6. Hammer: Hammers are used as
striking tools. These are classified
as:
a. Hand hammer.
b. Sledge hammer
c. Power hammer
fig : Hammer
7. Tongs: Tongs are used for
holding and turning hot metal
pieces. Depending upon their use,
tongs are classified into many
types. All types of tongs have
similar construction except the
mouth. A tong has two legs
riveted from a suitable place
Tongs
8. Punches and drifts: Punches
are made up of high carbon steel
and are used for making rough
holes in hot metal pieces.
Punches are available in different
sizes but have a common shape. A
drift is a large sized punch used
to enlarge a hole.
9. Flatters: As indicated by name,
flatters are used to flatten the
work piece. It has a plane face
joined with a straight shank. It is
held in a wire. The material of the
flatter is high carbon steel. The
body of a flatter is square in cross
section.
. Flatters

5. 10.. Fullers: Fullers are used for
grooving and drawing. These are made
in two pieces (lower and upper). Lower
part is mounted on the anvil and the
upper is held in hand from a wire
handle. These are made from high
carbon steel and medium carbon steel.
These are for hot work only. . Fullers
11`. Swages: Swages are used for
giving various shapes to the work pieces.
These are made up of high carbon steel
and are used in two pieces as in case of
fullers.
Swage
Types of forging:
There are basically three methods (or processes) to make a forged part.
1. Impression Die Forging
2. Cold Forging
3. Open Die Forging
4. Seamless Rolled Ring Forging
1. Impression die forging:
PROCESS OPERATIONS
Graphical depiction of process steps.
 Still Graphic
 Animated Sequence
 Video

6. Process Capabilities
Commonly referred to as closed-die forging, impression-die forging of steel, aluminum, titanium
and other alloys can produce an almost limitless variety of 3-D shapes that range in weight from
mere ounces up to more than 25 tons. Impression-die forgings are routinely produced on
hydraulic presses, mechanical presses and hammers, with capacities up to 50,000 tons, 20,000
tons and 50,000 lbs. respectively.
As the name implies, two or more dies containing impressions of the part shape are brought
together as forging stock undergoes plastic deformation. Because metal flow is restricted by the
die contours, this process can yield more complex shapes and closer tolerances than open-die
forging processes. Additional flexibility in forming both symmetrical and non- symmetrical
shapes comes from various preforming operations (sometimes bending) prior to forging in
finisher dies.
Part geometry's range from some of the easiest to forge simple spherical shapes, block-like
rectangular solids, and disc-like configurations to the most intricate components with thin and
long sections that incorporate thin webs and relatively high vertical projections like ribs and
bosses. Although many parts are generally symmetrical, others incorporate all sorts of design
elements (flanges, protrusions, holes, cavities, pockets, etc.) that combine to make the forging
very non-symmetrical. In addition, parts can be bent or curved in one or several planes, whether
they are basically longitudinal, equidimensional or flat.
Most engineering metals and alloys can be forged via conventional impression-die processes,
among them: carbon and alloy steels, tool steels, and stainless, aluminum and copper alloys, and
certain titanium alloys. Strain-rate and temperature-sensitive materials (magnesium, highly
alloyed nickel-based superalloys, refractory alloys and some titanium alloys) may require more
sophisticated forging processes and/or special equipment for forging in impression dies.
Cold Forging:
Most forging is done as hot work, at temperatures up to 2300 degrees F, however, a variation of
impression die forging is cold forging. Cold forging encompasses many processes -- bending,
cold drawing, cold heading, coining, extrusions and more, to yield a diverse range of part shapes.
The temperature of metals being cold forged may range from room temperature to several
hundred degrees.

7. ProcessOperations
Graphical depiction of process steps.
ProcessCapabilities
Cold forging encompasses many processes bending, cold drawing, cold heading, coining,
extrusion, punching, thread rolling and more to yield a diverse range of part shapes. These
include various shaft-like components, cup-shaped geometry's, hollow parts with stems and
shafts, all kinds of upset (headed) and bent configurations, as well as combinations.
Most recently, parts with radial flow like round configurations with center flanges, rectangular
parts, and non-axisymmetric parts with 3- and 6-fold symmetry have been produced by warm
extrusion. With cold forging of steel rod, wire, or bar, shaft-like parts with 3-plane bends and
headed design features are not uncommon.
Typical parts are most cost-effective in the range of 10 lbs. or less; symmetrical parts up to 7 lbs.
readily lend themselves to automated processing. Material options range form lower-alloy and
carbon steels to 300 and 400 series stainless, selected aluminum alloys, brass and bronze.
There are times when warm forging practices are selected over cold forging especially for higher
carbon grades of steel or where in-process anneals can be eliminated.
Often chosen for integral design features such as built-in flanges and bosses, cold forgings are
frequently used in automotive steering and suspension parts, antilock-braking systems, hardware,
defense components, and other applications where high strength, close tolerances and volume
production make them an economical choice.
In the process, a chemically lubricated bar slug is forced into a closed die under extreme
pressure. The unheated metal thus flows into the desired shape. As shown, forward extrusion
involves steel flow in the direction of the ram force. It is used when the diameter of the bar is to
be decreased and the length increased. Backward extrusion, where the metal flows opposite to
the ram force, generates hollow parts. In upsetting, the metal flows at right angles to the ram
force, increasing diameter and reducing length.