Forging is the process of metal shaping using force. Desired shape is obtained from any metal using compressive force at various temperatures and therefore the process is commonly classified as cold, warm or hot forging.

1. FORGING- THE ART OF CREATING PILLARS OF PROGRESS
Forging is the process of metal shaping using force. Desired shape is obtained from any metal
using compressive force at various temperatures and therefore the process is commonly
classified as cold, warm or hot forging. Forged metals are subjected to several other processes
such as turning and polishing to obtain the desired finished product.
The History of Forging
The process of forging dates back to as early as the 12th
century when the process would
involve hammering the metal on an anvil by a black smith. Though this conventional process
is still in vogue, modern industrial forging involves use of presses or hammers powered by
hydraulics, electricity or compressed air. The process of forging is used to achieve not only
the required shape but also the necessary strength for the finished product. A forged metal
piece is about 20 percent stronger than cast or machined ones.
Types of Forging
Some of the common forging processes are open die forging, closed die forging, roll forging,
press forging, automatic hot forging etc. The process could be done at various temperatures.
Depending on whether it is done above or below the re-crystallization temperature, it is
classified as hot forging or warm or cold forging. Open die forging involves hammer striking
the work piece which is placed on an open anvil, allowing it to flow and expand openly
during the process. This method is employed for artistic or customized smithing job or to give
a rough shape for further complex machining. In case of closed-die forging, the work piece is
placed in a mould which is attached to the anvil. As the hammer is dropped, the metal
expands and flows to fill up the die cavities. The process is usually carried out in several
stages before the final product is obtained. In case of closed-die forging, the initial cost of
infrastructure etc is high, but the recurring costs are low especially when larger volumes are
required to be manufactured.
Long and cylindrical metal pieces used for making assemblies such as axels of automobiles,
leaf springs and tapered levers are manufactured by a process called Rolled ring forging. This
is done by reducing the thickness of a round or flat work piece by inserting such a heated
metal bar into a set of rollers. The bar is moved progressively and thus the desired shape and
size is obtained.
Expensive Yet Econimical
Forging is a process used to produce high quality assemblies and sub assemblies for
sophisticated industrial applications such as aerospace, nuclear, military, power generation
etc. Forging requires high capital as it involves use of heavy and expensive tools and other
equipment. It also requires furnaces and infrastructure to sustain the vibration and shock
generated during the process.
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