COLLEGE OF EDUCATION AKWANGA,

NASARAWA STATE

ALLANANA DOLE JATAU

MATRIC NO. COEA/NCE/2019/TED/0143

LEVEL: NCE2

DEPT. TECHNICAL EDUCATION

COURSE: TED 211

ASSIGNMENT QUESTIONS
1. WHAT IS FORGING
2. TYPES OF FORGING
3. EXPLAIN EACH OF THEM
4. STATE THE ADVANTAGE AND DISADVANTAGE OF FORGING
5. USES OF FORGING
6. DRAW A FORGING
Number 1
What is Forging?   
At its most basic level, forging is the process of forming and shaping
metals through the use of hammering, pressing or rolling. The process
begins with starting stock, usually a cast ingot (or a "cogged" billet
which has already been forged from a cast ingot), which is heated to its
plastic deformation temperature, then upset or "kneaded" between
dies to the desired shape and size.
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, micro alloy steel, stainless steel, aluminum, and titanium.
Number 2
Types Of Forging
1. Drop Forging 
2. Press Forging
3. Upset Forging
4. Roll Forging
5. Net-Shape And Near-Net-Shape Forging
6. Isothermal Forging
Number 3
1. Drop Forging 
Drop forging may be a metal forming process. A workpiece is inserted
into a die then hammered until it’s assumed the form of the die. The
lower die could be a stationary part, while the upper part may be
a moving hammer dropped onto the workpiece so as to deform it. Drop
forging are often performed both at high or ambient temperature. This
manufacturing process includes a long tradition within the metal
shaping industry and it’s been used for many years. The mechanics
of the method are still the identical, but all involved machinery has
greatly advanced to show drop forging into a high-precision
manufacturing process. The same as all other forging techniques, drop
forging enhances the fabric properties of the ultimate piece.
There are two main tools used in forging machines to deform a stock
through extensive forces; for example, hammer or press. Drop hammer
hammers and press machines can produce the same results as the way
the force is transmitted from the forging die to the metal part is
fundamentally different, but the difference is that a forging hammer
affects the workpiece as a machine not by continuous pressure but by
sequential blows.
Consistent with the way a hammer is attached and also the way it
deforms the workpiece, there are differing types of forging hammers:
drop forging hammers are simplest configuration for forging is dole
out on a particular hammer and anvil, A lower die is fixed on the anvil
and an upper (moving) die is fixed on the ram and the ram and upper
die transfer fast-speed mechanical energy to the work piece,
placed within the lower die and anvil. The anvil configuration has
to provide a awfully solid base, since it absorbs an enormous amount of
the energy. Therefore the anvils’ weight is sometimes ten to twenty
times quite the burden of the hammer. Double-Acting Forging Hammer
configuration is comparable to the primary one, but the hammer fixed
on the ram is accelerated when falling by air or steam; respectively a
hydraulic or pneumatic forging hammer. Double-action forging
hammers are very powerful and gradually replace simpler
configurations, and there is no anvil in the Counterblow Forging
Hammer configuration. However, there are two hammers fixed on two
rams, achieving opposite directions that allow the workpieces to be
precisely formed[3].
These are the foremost complex forging hammers and that they allow
very large forging energy levels to be achieved. In terms of the position
of the dies, there are two main kinds of drop forging: open-die drop
forging and closed-die drop forging, also called impression-die forging.
Open-Die Forging 
This is additionally called smith forging. In open die forging, a hammer
hits and deforms the workpiece placed on a stationary anvil; it also gets
its name from the fact that dies do not surround the workpiece and
allow dies to flow outside where they come into contact, so it must
orient and position the workpiece so that it forces the specified shape.
Molds are flat. However, some have a specially shaped surface for
special processes; For example, a die may have a round, concave or
convex surface, or a tool or a cutting tool for forming holes. Open die
forgings work on sections such as discs, hubs, blocks, shafts, sleeves,
cylinders, flats, hexagons, circles, plates.
In some cases, open-die forging could also be employed to rough-shape
ingots to organize them for subsequent operations. Open-die
forging may orient the grain to extend strength within the required
direction. Advantages of open-die forging; reduce chance of voids, good
fatigue resistance, continuous grain flow, finer grain size, greater
strength, better response to thermal treatment, improvement of
internal quality, greater reliability of mechanical properties, ductility
and impact resistance. “Cogging” is that the successive deformation of
a bar along its length using an open-die drop press. It
is commonly accustomed work a bit of staple to the correct thickness.
Once the correct thickness is achieved the right width is achieved via
“edging”. “Edging” is that the process of concentrating
material employing a concave shaped open-die, the method is
named “edging” because it’s usually disbursed on the ends of the
workpiece. “Fullering” could be a similar process that thins out sections
of the forging employing a convex shaped die and these processes
prepare workpieces for further forging processes.
Impression-Die Forging
Impression-die forging is additionally called “closed-die forging”. In
impression-die forging, the metal is placed during a die resembling a
mold, which is attached to an anvil. Usually, the hammer die is
formed also and dropped on the workpiece, causing the metal to flow
and fill the die cavities. The hammer is mostly up-to-date with the
workpiece on the dimensions of milliseconds, looking on the scale and
complexity of the part, the hammer is also dropped multiple times in
quick succession. Excess metal is squeezed out of the die cavities,
forming what’s spoken as “flash”. The flash cools faster than the rest of
the material. This cold metal is stronger than the metal in the mold and
the result of this helps to prevent excessive flashing, while also forcing
the metal to fill the mold cavity completely. It is used to distribute
metal into subsequent cavities to the shape of the container and is
referred to as “edge”, “plump” or “bent” impression.
The subsequent cavities are called “blocking” cavities, during which the
piece is functioning into a shape that more closely resembles the
ultimate product. These stages usually impart the workpiece with
generous bends and huge fillets. The ultimate shape is forged during a
”final” or “finisher” impression cavity. If a short part is to be run, the
mold should lack a final gauge gap and instead it should be more
economical to process the final features. Impression die forging has
been improved through direct heat treatment of parts after forging,
due to the increased automation with heating and manipulation in
recent years, mechanical feeding, positioning. During this type of
forging, the die cavities are completely closed, which prevents the
workpiece from flashing. The most important advantage of this process
is that it minimizes much less metal loss during ignition. The flash can
make up almost 50% of the starting material, the disadvantages of this
process include the additional cost due to a complex mold design and
even the need for better lubrication and workpiece placement. There
are also other variations of part formation that integrate the impression
die forging process. A different method involves pouring a forging die
out of liquid metal.
The casting is removed after it’s solidified, but while still hot. It is then
finished in an exceedingly single cavity die. Flash is cut, then the part is
quenched and hardened. Another mode of operation is the same,
except that metal droplets are produced by spraying the collectors.
Closed die forging requires a design process to create cavities in the
working mold and involves a high initial cost of forming dies, but
becomes economical when large production is made as there are low
recurring costs for each part.
This is often one in all the main reasons closed-die forgings are
often utilized in the automotive and gear industries. One more
reason forgings are common in these industrial sectors is that forgings
generally have a couple of 20 percent higher strength-to-weight ratio
compared to cast or machined parts of the identicalmaterial. Design of
impression-die forgings and tooling. Forging dies are
usually manufactured from high-alloy or alloy steel. Dies can be impact
and wear-resistant, maintain strength at high temperatures, have the
power to resist cycles of rapid heating and cooling; that is to say, as to
provide a far better, more economical die the subsequent standards are
maintained: the dies part along one, flat plane whenever possible. If
not, the parting plane follows the contour of the part, the parting
surface may be a plane through the middle of the forging and not near
an upper or lower edge, adequate draft is provided; usually a minimum
of 3° for aluminium and 5° to 7° for steel, generous fillets and radii are
used, ribs are low and wide[6]. The various sections are balanced to
avoid difference in metal flow, dimensional tolerances can not closer
than necessary. Barrelling occurs when, because of friction between the
work piece and therefore the die or punch, the work piece bulges at its
centre in such some way on resemble a barrel. This ends up in the
central a part of the work piece to come backin touch with the
perimeters of the die ahead of if there have been no friction present,
creating a far greater increase within the pressure required for the
punch to complete the forging. Dimensions contained within a mold
part stand at a substantially high level of accuracy.
2. Press Forging
Press forging is placed between dies. It is the process of forming a
metal by applying mechanical or hydraulic pressure. Press forging is
done in a forging press and is a machine that results in gradual pressure
on the forging dies; furthermore, the shape of the metal is made by a
press stroke, processing for each mold station. The difference between
impact forging and press forging is that in impact forging, a rapid
impact force is applied to the die, but in press forging, a gradually
increasing pressure is applied to the die. Press forging is suitable for
forging efficiency for large-volume materials, and is a technique that
gradually applies pressure to a die holding a workpiece, and this
process is suitable for forging in open die or closed die; Open die press
forging is a process in which the metal is surrounded by a die on one
side. First, in the impression mold and closed die forging methods, the
metal material is taken into a mold, then pressure is applied to the
mold, then the plastic deformation of the material occurs and fills the
mold cavities. The closed mold method causes less flash than forging in
the open mold; Also, some of the press forging methods using closed
dies are coining and hubbing.
The hubbing is pressed into the mold so that the mold flows into the
mold cavities, and this process is often used in silverware making.
The three main types of forging presses used for press forging are listed
below:
Mechanical Press – converts the rotation of the motor into linear
motion of the ram.
Hydraulic Press – hydraulic motion of the piston moves the ram.
Screw press – screw mechanism actuates the ram movement.
Advantages of forging pressing are as follows; Suitable for controlling
the compression ratio of the workpiece, economically suitable for high
volume production, most shapes can be made, and produce less scrap.
3. Upset Forging
Upset forging which is a manufacturing process, that plastically deforms
metal under high pressure into good strength components of varying
sizes and this forging process is right for extended shapes where just
one end of part has tobe forged. Upset forgings can be made by
gathering material to a delegated area of a carbon, alloy, and stainless-
steel bar. The press accustomed manufacture these components
operates on a horizontal plane. The dies are split to permit material to
protrude beyond the machine, and a few of the forming force is
provided by a third die attached to the header.
4. Roll Forging
Roll forging could be a process where round or flat bar stock is reduced
in thickness and increased long. Roll forging is made using a cylindrical
or semi-cylindrical roller with grooves; Further, a heated rod is inserted
into the rollers, after which the rollers rotate, gradually shaped as it is
rolled on the machine.
The piece is then transferred to the following set of grooves
or circled and reinserted into the identical grooves. This continues
until the specified shape and size is achieved. The advantage of this
process is there’s no flash and it imparts a good grain structure into the
workpiece. For example, for this method include axles, tapered levers
and leaf springs.
5. Net-Shape And Near-Net-Shape Forging
This process is additionally referred to as precision forging. It absolutely
was developed to attenuate cost and waste related to post-forging
operations. Therefore, the ultimate product from a precision forging
needs little or no final machining. Cost savings are gained from the
utilization of less material, and thus less scrap, the decrease in energy
used, and therefore the reduction or elimination of machining.
Precision forging require less of a draft, 1° to 0°. The downside of this
process is its cost, therefore it’s only implemented if significant cost
reduction are often achieved. Cold forging Near net shape forging
is most typical when parts are forged without heating the slug, bar or
billet. Aluminum could be acommon material which will be cold
forged counting on final shape. Lubrication of the parts being formed is
critical to extend the lifetime of the mating dies[8].
6. Isothermal Forging
Isothermal forging is a hot machining process that tries to look at the
workpiece at high temperature, and this can be achieved by heating the
die to or slightly below the initial workpiece temperature; furthermore,
cooling of the workpiece between the mold work interface is
eliminated as the forces applied by the mold create the work. As a
result, the flow properties of the metal are significantly improved.
 Isothermal forging may or might not be performed in a veryvacuum.
Equipment costs for this manufacturing process are high, and also
the added expense of this kind of operation should be justified on a
case by case basis. The benefits of isothermal forging are its low
machining requirements, low scrap rates, part repeatability and, finally,
close to clear shapes, which encourage the use of small machines for
forging due to low heat loss[9]. There are also disadvantages, these are;
higher die material costs because of the temperature and pressure,
require uniform heating systems, protective atmospheres or vacuum to
reduce oxidation of the dies and material, and low production rates.

Number 4
Forging Advantages And Disadvantages
The forging process can produce a part with better performance than
cast materials and machined materials; because during the forging
process the internal grain texture is deformed to follow the general
shape of the part; the result is a part with improved strength
properties. In addition, forged parts can be produced with lower
economic loss than casting or fabrication. Considering factoring and
quality in all costs and scrap costs that arise from the initial state of a
product to its finalization, forging processes provide more benefits in
long periods. Hot forging, secondary processing on the part is more
advantageous than cold forming; Also, in a few cases; Other methods of
hardening the part, for example heat treatment, are generally more
economical and also controllable. In general, materials such as
aluminum alloys and titanium will be hot forged followed by hardening,
as alloys are prone to precipitation hardening. In the case of hot
forging, a high temperature furnace is required to heat the ingots or
logs; Due to the size of large forging hammers and presses, the parts to
be produced, and the dangers of working with hot metal, a special area
is required for processing and protection; In the case of drop forging
operations, it is done to prevent the shock and vibration generated by
the hammer. Most forging operations require proper shaping of the
workpiece, which requires careful processing and thorough heat
treatment. Metal forming molds are used for these processes. There
are many forging methods; However, forging is divided into three main
classes;
Drawn out: length increases, cross-section decreases
Upset: length decreases, cross-section increases
Squeezed in closed compression dies: produces multidirectional flow
Common forging operations; rolling, forging, gear forging, open die
forging, printing die forging (close die forging), press forging, cold
forging, all forging operations are carried out at various temperatures;
however, the classification process is based on whether the metal
temperature is above or below the recrystallization temperature. If the
temperature is above the material’s recrystallization
temperature it’s deemed hot forging; if the temperature is below the
material’s recrystallization temperature but above 30% of the
recrystallization temperature. If below 30% of the recrystallization
temperature (usually room temperature) then it’s deemed cold
forging. The advantages of hot forging are faster and more precise and
the metal is deformed. Therefore, the hardening effects are eliminated
by the recrystallization process. Cold forging typically leads to work
hardening of the piece.
NUMBER 5
Uses of forging

 Aerospace. Aircraft Engines. Airframe and auxiliary

equipment.

 Guided missiles and space vehicles.

 Automotive. Passenger cars. ...

 Bearings, ball and roller.

 Electric power generation/transmission.

 Industrial and commercial. machinery and equipment.

 Hand Tools.

 Industrial tools. ETC.

Number 6
References
https://www.farinia.com
https://www.maschinenmarkt.international
https://yenaengineering.nl
https://www.thomasnet.com

https://www.scotforge.comM