What is cold forging?
As a major metal fabrication, forging is a metal forming technique that uses localized forces of
compression. Forgings have undergone major changes that lead to more efficient, faster and more
durable processes. Today’s forging is usually done using electric, hydraulic or compressed air driven
forging presses or hammer tools.
Cold forging, unlike hot forging, deforms metal below its recrystallization point - near or at room
temperature. Cold forging is a preferred method for softer metals (such as aluminum), is less
expensive and has the ability to produce forged parts that require little finishing.
A cold machining process, cold forging involves placing bar material in a die and then pressing it with
a second closed die.
Similar to the cold press process (except that cold forging uses vertical presses instead of horizontal
cold press machines), the workpiece is pressed between two dies until it assumes the desired shape
of the die.
Deformation occurs at room temperature, changing the size and shape of the metal. This forging
method is volume specific and generally complements cold pressing, adding more complex shapes to
the blank used in cold pressing.
The basic equipment used for the forging method includes vertical presses, either fully automatic or
manual. These vertical presses can be driven either hydraulically or mechanically.
A reliable and cost-effective process that includes producing parts for the electric car industry:
Parts for car seats and alternators (such as the claw-pole).
Different types of gears used on other parts.
Parts for starter motors such as transmission solenoid body, core and plunger, to name but a few
examples).
Motorcycle parts such as those for flywheel magnetos.
Parts that are hollow with shafts and stems.
Parts used for valves and switches.
Cold forging is also used to produce anti-vibration spiders and parts.
The benefits of cold forging
This particular forging process, offers manufacturers a number of advantages, including..
Cold forging does not require heating.
This forging process offers better interchangeability and reproducibility.
Better surface finish is achieved and contamination problems are minimized.
Cold forging offers superior dimensional control.
The ability to assign targeted properties to the metal formed.
The disadvantages of cold forging
Cold forging has the following disadvantages
The production of an undesirable residual stress.
The forged metals are less ductile and higher forces are required in cold forging.
Because of the higher forces required in this process, heavier and more powerful equipment is
needed, as well as stronger tools.
Although the metal can acquire directional properties, these properties can be detrimental.
The surfaces of the metals used must be clean and free of tarnish.
Because of the loss of ductility associated with stress hardening, intermediate annealing may be
necessary.
What is hot forging?
As a major metal fabrication, forging is a metal forming technique that uses localized forces of
compression. Forgings have undergone major changes that lead to more efficient, faster and more
durable processes. Today’s forging is usually done using electric, hydraulic or compressed air driven
forging presses or hammer tools.
Hot forging involves heating a workpiece to about 75% of its melting temperature. This reduces the
yield stress and energy required to form the metal, effectively increasing the production rate (or strain
rate). Hot forging helps make the metal easier to form and less likely to break.
Iron and its alloys are almost always hot forged for two main reasons..
1. As the work hardens, hard materials (such as steel and iron) will be harder to machine, and
2. it is more economical to hot forge metals such as steel and then follow with heat treatment
processes, since metals such as steel can be strengthened through other processes (and not
necessarily just cold working processes).
While other materials must be strengthened by the forging process itself, materials such as most
titanium and aluminum alloys can be hot forged and then hardened.
Average temperatures for hot forging includes..
Aluminum (Al) Alloys - 360° (680°F) to 520°C (968°F)
Copper (Cu) Alloys - 700°C (1 292°F) - 800°C (1 472°F)
Steel – up to 1 150°C (2 102°F)
In hot forging, the temperature is above the recrystallization point of the metal formed. Because it is a
process in which metals are plastically deformed above their recrystallization temperature, these high
temperatures are necessary to prevent strain hardening during the deformation.
In this process, the metal is usually heated (above its recrystallization point) after which it is struck into
a die - depending on requirements, this die may also be heated. Because the metal is hot, it "moves"
easily and manufacturers can make more elaborate shapes than in cold forging.
For superalloys (which have low malleability), processes such as isothermal forging - where
deformation takes place in a controlled atmosphere - are used to prevent oxidation.
Isothermal forging, also known as hot die forging, is a hot working process in which the workpiece is
maintained at its maximum elevated temperature throughout the forming process.
This temperature is maintained by heating the die - it will be at the temperature of, or slightly below,
the elevated temperature of the workpiece. The forces exerted by this die shape the workpiece and,
because the die is also at an elevated temperature, cooling of the workpiece between the die-work
interface is eliminated. This, in turn, results in an improvement in the flow properties of the metal
(workpiece).
It should be noted that isothermal forging can also be performed in vacuum.
Hot forging dies
The dies used in hot forging undergo heavy thermal cycling and mechanical stress. This in turn affects
the life of the die, as the die is open to..
Coarse cracking
Plastic deformation
Thermal fatigue cracking
Wear
Depending on the type of forging operation, the material and the size of the part being formed, to
name but a few, forging dies must have the following properties and characteristics..
A sufficient hardness and the ability to maintain this hardness at elevated temperatures.
A sufficient hardness and resistance to fatigue.
A good ductility and toughness in all directions at both high and low temperatures.
Higher levels of both hot hardness and hot tensile strength.
The Benefits of Hot Forging
Hot forging, which is often used for the types of parts that affect engineering applications, is also a
recommended process for deforming metals with a high deformation ratio.
The advantages of hot forging includes
An increased ductility.
Because of the decrease in yield strength, it takes less energy (or force) to work with the material.
During hot forging and subsequent deformation, pores can reduce (in size) or close completely.
Because the elevated temperatures increase diffusion it is possible, in turn, to reduce or remove
chemical inhomogeneity.
In hot forging steel, the weak and ductile FCC (face-centered cubic) austenite is deformed instead of the
strong BCC (body-centered cubic) ferrite – which would deform at lower forging temperatures.
The Disadvantages of Hot Forging
Hot working, as all metal forming processes, also has a set of disadvantages. These disadvantages
include..
The result of a less precise tolerance caused by warping and thermal contraction. This is caused in
instances where uneven cooling is present.
There is the possibility that the grain structure may vary throughout the metal.
With hot working, there is also the possibility of an undesirable reaction between the metal being forged
and the surrounding atmosphere.
