Forging is a process that involves shaping metal by heating and hammering. It increases strength and toughness by producing directional grains that refine the metal's structure, eliminating defects like cracks and pores. Forged components can withstand high loads, be produced to close tolerances, and require less machining than casted parts, reducing costs. Common forging operations include upsetting, drawing down, bending, punching, drifting, and swaging.

1.  “The process of giving a desired shape to a metal piece
by heating and hammering is known as forging”.
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2.  It increase the strength and toughness of the metals by
producing directional grains.
 It refines the structure of the metal and thus renders it
more dense.
 The internal defects like segregation, cracks and
porosity are eliminated.
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3.  A forged component has the ability to withstand
higher load during service.
 A forged components can be produced to close
tolerance.
 It reduces the machining time, material and labor
considerably.
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4.  Brittle material like cast iron cannot be forged.
 Complex shapes can easily be produced by casting and
not by forging.
 Cost of forging dies is high.
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5.  Upsetting:
upsetting is the process in which the cross
sectional diameter of a hot metal work piece is
increased with a corresponding reduction in its length.
During this process the hot metal piece is held in a tong
and placed on the anvil in vertical position and then is
stroke with a hammer.
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6. Hamza Abdullah Khan... IIUI

7. Hamza Abdullah Khan... IIUI

8.  It is also known as drawing down.
 Exactly the reverse of upsetting
 Contrary to upsetting this process is used to reduce the
thickness/width/diameters or increasing the length of
red hot workpiece.
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9.  Cutting operation is required for removing extra metal
from the job.
 For cutting operation three major things required,
hammer, cutting tool set and the stock.
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10.  The process of giving the desired angle or curves to a
hot metal work piece is known as bending.
 The process is done on the edge of anvil.
 Circular shaped, eye bolts, hooks or any other types of
bent shape can be prepared with this operation.
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11.  Punching is the operation in which a rough hole is
made into the hot workpiece by forcing a punch
through it.
 A red hot job is placed on the anvil and by using a
sledge hammer, the punch is forced to the pierce the
metal upto half of its thickness.
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12.  Then by inverting the workpiece same process is
repeated at the same point to get a rough hole.
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13.  Is an operation of finishing and enlarging the hole by
hammering a tapered drift into the hole until the
required bore size is reached.
 Is similar to punching and followed by it.
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14.  Swaging is the operation of reducing and finishing a
work piece to different desired shapes usually circular,
hexagonal and square.
 Swaging operation is performed with the help of
swages and swag blocks.
 Swages are used for small jobs.
 Swag blocks are used for large jobs.
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15.  It is the operation of reducing the thickness of a work
piece.
 In this process the bottom fuller is held in the hole of
the anvil.
 Hot work piece is placed in the grooves of the lower
fuller and then the top fuller is placed over it.
 The hammering operation is carried out until the
piece gets squared thickness.
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16.  This operation is performed to level the job surface.
 The red hot metal work piece is placed on the anvil
and is stroked hardly using hammer set to flatten the
metal work piece.
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17.  The process of joining two metals by heating and
hammering is known as forge welding.
 The metal pieces to be joined are cleaned and heated
in a furnace up to the welding temperature.
 With the help of tongs these are kept overlapping each
other at the one of their ends on the anvil and are
subjected to hammering.
Hamza Abdullah Khan... IIUI

18. Hamza Abdullah Khan... IIUI

19.  Forge/Furnace/Hearth : Heating furnace
 Anvil :Supporting Tool
 Hammers & set Hammers : Striking Tool
 Tongs: Holding Tool
 Chisels: Cutting Or Shaping Tool
 Fullers: Grooving Tool
 Swages & Swage Block: Shaping Tools
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20. Hammers
Tong chisel
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Swage Block

21.  Pitting: occurs on the surface of forging due to scales.
 Cold shuts or laps : Short cracks that occurs on the
corners of the surface that are at right angles to each
other
 Die shift : Caused due to misalignment between to
halves of forging dies.
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22.  Dents :Caused due to careless working.
 Oxidation & Decarburization : Occur due to
overheating of stock.
 Fins and rags : Small projection or loose metal driven
into the forging surface
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23.  Some other common defect are
(a) Incomplete filing of dies
(b) Burnt and overheated metals
(c) Flakes: Internal breaks and rupture
(d) Incorrect size of forging
(e) Tears
(f) Blowholes
(g) Internal cracks
Hamza Abdullah Khan... IIUI