Views: 19 Author: Site Editor Publish Time: 2022-03-31 Origin: Site
Cold Forging Process is one of the most common manufacturing processes which shapes a metal piece through applying compressive forces on it. Forging can be performed in different temperature conditions, such as cold forging, hot forging, warm forging. The forging process takes hammers plus presses to squeeze to deform the material into very high strength parts.
The forging manufacturing process is totally different from the casting method, where the whole molten material is inserted into a mold (see the difference between casting and forging). Another most significant benefit over the other manufacturing processes (such as casting and machining) is here, while forging improves the all mechanical properties of the given material by pouring its grain structure and making it more stronger and tougher. This makes the forging serveable in different industrial applications.
Here in this article, we will explain in detail about cold forging and its advantages as well as hot forging and its advantages, their differences, cost expenditures, etc., in detail.
The hot forging process absorbs the application of an extreme heat, along with the required temperature that depends on the specific type of metal. For example, the average temperature needs for deforming steel is about approximately 2,100 degrees Fahrenheit; and it is specifically for aluminum alloys, on the other hand, the temperature range is about 680 to 970 degrees Fahrenheit; and that is specifically for copper alloys, the range is 1,300 to 1,470 degrees Fahrenheit. The high temperature essentially required to prevent strain becoming hard during deformation.
Hot forging is considered the best choice for all steel forgings that are used in technical applications along with deforming metal which has a very high formability ratio.
lhomogenized grain structure: Porosity free surface that makes quality enables for a wide range of completion methods /operations like polishing or surfacing treatment.
llow work hardening,
lincreased ductility: Parts have high ductility that makes them desirable for all types of configurations.
lreduction in chemical inconsistencies.
lEfficient method when it working with harder metals like steel
On the downside, hot forging provides less precise tolerances, the potential that is required for warping during cooling along with the possibility regarding an adverse reaction between the surrounding environment and the metal.
Cold forging deforms the metal whereas it is below from its recrystallization point. Cold forging is usually preferred when the metal is already a very soft metal, like for example aluminum. This process is generally less expensive than that of hot forging and the ending product requires little, or no finishing work. Oftentimes, when aluminum is usually cold forged into a given shape, it is the heat that is treated to strengthen the piece. This is also called “tempering.”
Despite the word “cold,” cold forging actually happens at or near according to room temperature. And The most generic metals in cold forging that require for applications are usually carbon alloy steels or standard alloy steel. One of the most important types of cold forging regarding a process also called impression-die forging, where the metal is always placed into a quality die that is affixed to an anvil. The metal is when it is hit by a descending hammer meaning hammering it in descending order and pushed into the die. Depending on the product type, the hammer can actually be dropped on the surface of metal various times in a very rapid sequence.
Forging processes, be it cold or hot forging, are generally not considered to be an energy saving or eco-friendly part of the all manufacturing process, but luckily cold forging is certainly the most common eco-friendly process of its unique kind in operation today. For those companies that care too much about reducing the carbon footprint of their nasty products, the cold forging process would help to reduce waste and lessen energy uses as compared to compared to forging substitutes or alternatives that uses the heat.
Other reasons or advantages that stress why the cold forming process is the best and authentic or preferred choice include the:
lHigh quality of the surfacing material
lConsistency to all & each part manufactured
lEfficient usage of material.
In addition to the reasons that we listed above and due to the eco-friendly factors, cold forming is also considered one of the most cost-effective or cost-saving methods of forging in today’s market. For example, estimates show that this process may reduce your cost as much as 40 to 60%!
However, there are mainly 4 important factors that always determine the final quote of a forged component. These are:
lThe chunk of the used material;
lForging costs as tools, electricity, investments, etc;
lPost-forging heat treatments;
lAdditional operations quality control tests and shot blasting.
Cost optimization in the process of cold forging usually starts with the raw material. To obtain the most and most cost efficiency you should manage the manufacturing process with great know-how and involve all tools and techniques. For instance, large batches of the cold extruded elements are manufactured on very high speed mechanical presses, but at the same time complex parts plus small series instead of hydraulic presses.
The minimization of the energy cost during hot forging is high concern of every manufacturer along with following innovative technologies:
lMetallurgy: consolidated vacuum and powder metallurgy
lSurface treatment: duplex treatment and nitriding, carburizing.
One of the most important differences of cold forging regarding a process also called impression-die forging, where the metal is always placed into a quality die that is affixed to an anvil. The metal is when it is hit by a descending hammer, meaning hammering it in descending order and pushed into the die. Depending on the product type, the hammer can actually be dropped on the surface of metal various times in a very rapid sequence.
On the other hand, Hot forging is considered the best choice for all steel forgings that are used in technical applications along with deforming metal which has a very high formability ratio. Key advantages of hot forging
Winshare provides warm, cold, and hot forging or may be the combination of all three different processes to address several customer demands, and both performed in excellent conditions with the state-of-the-art machinery required for perfect results. We work closely and carefully with our customers by understanding their specific needs along with the best possible solution.
Finally, a manufacturer can choose one forging process over the other because of the economical and quality reasons. The decision should be based on the required and essential functions of the desired component, from the specified industry and if it is a mass production plus a low volume of customized parts.