Forging changes a metal workpiece through compression at either cold, warm, or hot temperatures. Cold forging improves the strength of the metal by hardening it at room temperature. Hot forging results in optimal yield strength, low hardness, and high ductility by hardening the metal at extremely high temperatures. Whether to use hot or cold forging depends on the finished component’s function, industry, and production volume.

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Hot Vs Cold Forging

While cold forging compresses metal at room temperature, hot forging requires high heat. A primary differentiator of cold and hot forging is that the high heat of hot forging allows the metal to take on more elaborate and complex forms than cold forging.

Hot Forging

The hot forging temperature varies depending on the type of metal. Hot forging starts with heating the dies to prevent any loss of temperature during the process and ensure crystallization doesn’t occur until forming is complete. Heating causes the metal to become more ductile. When the pressure of the dies squeezes the hot metal, the structure transforms into a more refined grain that results in increased yield strength and ductility.

Factors to consider when hot forging include:

• Cooling. If the metal cools to a temperature lower than the minimum threshold, it completes the forging. The metal must be reheated if this occurs before achieving the final shape.
• Tolerances. Dimensional tolerances with hot forging are less precise than cold forging.
• Dies. Hot forging dies are custom-made to the customer’s part specifications.

Cold Forging

Cold forging uses a displacement process to shape the material into the desired shape. Compressive force squeezes the metal between a punch and die at room temperature until the material conforms to the die’s contours. Cold forging techniques include rolling, pressing, drawing, spinning, heading, and extruding.

Factors to consider when cold forging include:

• Material volume. Careful control over the material volume prevents stress and damage, particularly in closed forging, as the excess has nowhere to escape.
• Bonderizing. This coating process improves material flow during the process to reduce force, stress, and friction while improving surface quality.
• Annealing. Annealing softens the metal, improving the material flow. It can be applied as an intermediate process when work hardening occurs before the forging process is completed.
• Lubrication. Lubrication is critical during cold forging. High-viscosity oil protects against metal-on-metal friction and applying thin oil dissipates heat.

Advantages & Disadvantages Of Hot And Cold Forging

Advantages of hot and cold forging include:

• Hot forging. Increased ductility for more complex parts and allows for more options for customization
• Cold forging. Creates no waste, requires little to no finishing work, maintains dimensional accuracy, and results in high surface quality.

Disadvantages of hot and cold forging include:

• Hot forging. Additional cost for heat treatment, less precise dimensional tolerance, risk of warping
• Cold forging. Few options for customization, risk of residual stress, may require heat treatment

High Quality Forging From Cornell Forge

A forging manufacturer offers cost-effective opportunities to businesses in many industries. They produce strong and reliable products, and can customize each component to help businesses meet specific goals.

Keep reading to learn more about what forging is and why you should consider working with a professional forging manufacturer.

What Is Forging?

The forging process involves deforming and manipulating metals into finished products, oftentimes using heat to aid in material movement.

Types of Forging Processes

Typically, forging manufacturers use one of four methods to produce forged products. The practices include impression die forging, cold forging, open-die forging, and seamless rolled ring forging. Each process delivers unique benefits when applied to specific materials.

Impression Die

Impression die forging is a preferred method for steel, aluminum, titanium, and other alloys. These forgings are often made using hydraulic presses, mechanical presses, and either power-driven or gravity drop hammers.

This forging process is well-known for its ability to create seemingly limitless 3D possibilities. Other benefits of this process include:

• Reduced Waste
• Improved Production Rates
• Improved Impact Resistance
• Better Strength-to-Weight Ratios

Cold Forging

While the majority of hot-forging work is conducted at temperatures of around 2,300 degrees Fahrenheit (for steel), cold forging is different. This unique process involves methods like extrusion, heading, or upsetting, and is conducted at room temperature through compressive force.

Though it can be done on tough materials, relatively soft metals, including gold, silver, copper, and brass benefit the most from this technique. Benefits of cold forging include:

• More Refined Surface Finishes
• Cost-Effective
• Minimal to Zero Waste
• Longevity
• Improved Tensile Strength

A manufacturer may also choose this method to design automotive parts involved with steering and suspension. It remains an economical choice across a wide range of industries.

Open-Die

This method produces forgings as light as a few pounds to upwards of 150 tons. Its name comes from the fact that the workpiece is not laterally confined by the walls of an impression, as would be in closed-die or impression-die forging. The practice allows a forging manufacturer to create an exponentially wide array of shapes and sizes. The top benefits of the open-die process include:

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• Enhanced Fatigue Resistance
• Increased Strength
• Durability
• Finer Metal Grain Sizes

This forging process utilizes striking or forming tools instead of enclosed impressions, which is why it’s a preferred method when manufacturing very large components.

Seamless Rolled Ring

The seamless rolled ring is a popular forging method for manufacturing mining, aerospace, energy, and heavy-duty components. This method involves piercing a hole in a large round piece of metal and compressing the inner and outer diameters between forming rollers as it is spun. The final products can range from mere inches to upwards of 30 feet. The seamless rolled ring process delivers the following benefits:

• Superior Structural Integrity
• Fewer Weaknesses

Forged rings remain a preferred choice when creating torque- and pressure-resistant components. The commonly used materials include carbon and alloy steels and non-ferrous materials.

Benefits of Forging

Metal-based products crafted by a forging manufacturer are typically superior to those made through casting or machining processes. That’s largely because the original grain flow from the steel making process is retained, optimized, or improved when forming a desired shape and size. Other reasons to opt for professional forging include:

• Stronger Products
• More Reliable & Commercially Safe Components
• Custom Solutions & Innovative Designs
• Consistent & Improved Metallurgical Properties

Industries That Rely on Forging Manufacturers

Forging manufacturers must meet the demands of industries that need solid and reliable solutions. Some of the industries that rely on forging, include:

Agricultural

The agricultural sector has significant forging needs. Farming components, including combine fingers, sickle heads, U-joins, and tie rods are robustly forged parts.  

Construction

Architects and contractors are tasked with finding innovative solutions for extreme load-bearing structures. Forging manufacturers remain the go-to solution when other metallurgical methods fall short.

Automotive

Many automotive companies, including household names like Ford and Chevrolet, rely on forging manufacturing for ball joint housings, exhaust flanges, suspension parts, and much more.

Commercial Truck & Transportation

Class 8 commercial motor vehicles require the strongest and most reliable metal parts possible. A tractor-trailer can weigh upwards of 80,000 pounds when hauling loads—that’s why torque-resistant forged parts are critical to safety.

Defense

The brave men and women who serve our country deserve the enhanced protection of forged metal products. Forging manufacturers provide the metal parts that help harden our country’s defenses.

Marine

Marine hardware must stand up to severe weather, the effects of saltwater, and pressure. That’s why shipwrights and boating repair facilities rely on manufacturers to produce forged bolts, spindles, bearing plates, and watertight door hardware.

Mining & Forestry

The heavy-duty equipment required for mining and forestry operations must withstand excessive force and hard impacts. If rock tools, hammerheads, and block cutters falter, everyday people could be placed in harm’s way.

Power Transmission

Driveshafts incur among the highest torque rates on a car, truck, or SUV. Auto manufacturers rely on only the most reliable power transmission parts possible to ensure driver safety. Forging  processes enhance parts strength and make vehicles roadworthy.

Railroad

America’s supply chains rely on intermodal transportation, and our railroads join truckers in delivering goods and materials to communities. Forged metal parts, including boxcar handle brakes, locomotive pins, and grab irons are central to keeping trains running on time.  

Common Duties of a Forging Manufacturer

A forging manufacturer has one primary duty—to deliver the highest quality parts and solutions possible. Meeting that responsibility requires years of experience, expertise in wide-reaching forging processes, and a daily commitment to excellence. Other capabilities of a forging manufacturer may include heat treatment, machining, coating, and more.

What to Look for in a Forging Manufacturer

If you need durable metal products or innovative solutions, it’s crucial to conduct research before working with a manufacturer. Consider an organization’s years of experience, certifications, record for on-time deliveries, and their ability to bring creative solutions to the table. Additionally, be sure they do not outsource their work to a foreign company.

Why Choose Trenton Forging?

Trenton Forging has been an industry leader since . As an American forging company, we produce all of our parts in-house, right here in the United States. Our commitment to quality is the reason why we have a long list of satisfied clients. We provide a wide array of services, including impression-die forging, machining, and coating, and assist clients in many industries.

The company is the world’s best cold forging press machine supplier. We are your one-stop shop for all needs. Our staff are highly-specialized and will help you find the product you need.

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