Forging Press

Contact Companies

Please fill out the following form to submit a Request for Quote to any of the following companies listed on

You can find more information on our web, so please take a look.

Get Your Company Listed on this Power Page

Introduction

The content of this article contains information regarding forging presses and their use.

You will learn:

• What is a Forging Press?
• Forging Press Process
• Advantages of a Forging Press
• Metals Used in a Forging Press
• And much more &#;

Chapter One &#; What is a Forging Press?

A forging press operates by utilizing a vertical ram to exert gradual and controlled pressure on a die containing a workpiece. This method is akin to drop forging, but it employs steady pressure rather than repetitive blows. The gradual movement of the ram allows for deeper penetration into the workpiece, resulting in uniform plastic deformation.

Forging press dies come in two main types: open and closed. In open die forging, the die does not fully enclose the workpiece, whereas in closed die forging&#;also known as impression die forging&#;the die fully encases the workpiece.

Forging presses use either hydraulic or mechanical force to apply pressure. Mechanical presses utilize a flywheel to store energy, which is then transferred through a crank mechanism to move the ram. These presses can deliver up to 12,000 tons of pressure.

Hydraulic forging presses, in contrast, generate force using high-pressure fluid. These presses are capable of producing up to 75,000 tons of force, making them suitable for more demanding applications.

Forging presses come in different types based on their size and the level of force they apply to achieve plastic deformation of the workpiece.

Chapter Two &#; What are the different types of forging presses?

The core aspect of forging operations is the capability to generate and concentrate substantial force on a workpiece. High-performance forging presses deliver significant power to deform and plasticize metals to achieve precise tolerances and shapes, utilizing either open or closed dies. Numerous methods exist to produce the required force, and these methods are distinguished by their mechanisms.

Forging presses can also be categorized based on their frame design, which can be either straight-sided or C-frame. Straight-sided presses feature two parallel sides, while C-frame presses have one side open.

The most basic type of forging press is a mechanical press that has a ram that moves vertically to apply pressure and squeeze a workpiece into the desired shape. This type of forging press is different from the old hammer-and anvil-method of ancient times that deformed materials using a series of blows. Other types of forging presses include hydraulic, screw, and upsetters, each of which produce the same shapes and can forge alloys with moderate ductility that would shatter under the impact of a hammer.

Hydraulic Forging Presses

Hydraulic presses generate force using hydraulic pressure, based on Pascal's Law. By applying a small force to a fluid, a larger amount of fluid is displaced to create the significant force needed to move the ram and shape the workpiece. These presses typically operate more slowly compared to other types and have extended contact times with the workpiece.

Hydraulic forging commonly uses open dies. The process is particularly suitable for isothermal forging due to its slow compression rate. Hydraulic forging presses can handle up to 50,000 tons, with dies measuring up to 12 feet by 32 feet.

Hydraulic forging dies endure significant wear because of the extended contact time, which reduces their lifespan. The duration of contact varies depending on the extent of deformation required.

Parts of a Hydraulic Forging Press

• Safety Door: The safety door is a correction gate.
• Limit Switch: The limit switch limits the amount of movement past a certain point.
• Manual Control Valve: The manual control valve allows for control of the operation.
• Relief Valve: The relief valve controls hydraulic pressure.
• Pressure Gauge: The pressure gauge gives a reading of the pressure.
• Hydraulic Cylinder: The hydraulic cylinder applies unidirectional stroke force.
• Oil Tank: The oil tank stores the hydraulic fluid.
• Pressing Plate: The pressing plate applies pressure to the workpiece.

Mechanical Forging Presses

Mechanical forging presses operate using a motor and a controller equipped with a clutch and crankshaft, which ensures a consistent stroke length for the ram. The ram reaches its highest speed in the middle of the stroke, achieving maximum force at the stroke's bottom. Automatic knockout or liftout pins are used to eject the forged item from the die.

The mechanical forging process exerts significant stress on the dies while applying minimal impact load. To prevent damage and breakage, harder dies are employed. The costs associated with tooling and die fabrication for mechanical forging presses are considerable. Additionally, the time required to change dies is long and labor-intensive.

Advancements in technology have enhanced the production rates of mechanical forging presses, with many now capable of achieving up to 70 strokes per minute, thus reducing labor costs.

Parts of a Mechanical Forging Press

• Motor: The motor supplies the power to the forging press.
• Ram: The ram is the connection between the board and the upper half of the die.
• Die: The die has two halves with one half connected to the ram with the bottom half setting on the base.
• Anvil: The anvil holds the bottom half of the die.
• Bailing Compartment: The bailing compartment is where the workpiece is placed to be shaped.

Screw Forging Process

Similar to hydraulic presses, screw presses operate at a slower pace. A motor drives a screw that applies a continuous pressure by pushing the ram down onto the workpiece with a long stroke. Screw presses are capable of generating forces up to 31,000 tons.

• Friction Drive Forging Presses - In a friction drive forging press, vertically mounted drive wheels rotate continuously. To make the downstroke of the ram, the wheels shift to enable one wheel to engage the flywheel to accelerate the ram. When the supplied energy is used, the flywheel, screw, and ram stop. At the stopping point, the drive wheels shift to allow the flywheel to reverse and move the ram to the top.
• Direct Electric Drive Forging Presses - With a direct electric drive forging press, a reversible electric motor is built into the screw and frame. The screw is threaded into the ram assembly. As with friction drive forging presses, when the flywheel stops, it must be reversed. In the case of direct electric drive forging presses, reversing is provided by the electric motor.
• Gear Drive Forging Presses - A gear drive forging press has a gear drive and slipping clutch flywheel assembly where the drive gears and screw are protected from overloading by the slipping clutch. They can have hydraulic or electric drive motors and are the largest type of screw forging press with ratings of 16,000 tons.

Servo Forging Process

A servo forging press utilizes a servo motor to drive an eccentric gear, which then produces slider movement. The motor's driving force is converted into linear motion through a system of screws, cranks, and elbow rods, which control the slider's movement. The stroke, speed, and pressure of the slider are regulated by sophisticated electronic controls. Servo forging presses are equipped with a main drive, an actuator, and an auxiliary mechanism.

The transmission mechanism of a servo motor forging press transfers energy from the servo motor to the actuator that drives the slider to do the reciprocating motion and complete the forging process. Servo motor forging presses have limited torque and are only suitable for low tonnage forging.

Servo motor forging presses offer precise control over the slider's speed and are adept at producing complex parts. These presses are designed to be energy-efficient, environmentally friendly, versatile, and equipped with advanced intelligence for manufacturing.

Advantages of Servo Motor Forging Presses

• Production Efficiency - Each aspect of the process can be set to a specific value and forming speed.
• High Quality - The position siding block can be adjusted and changed to produce tolerances of ± 0. in (0.01 mm).
• Low Noise - This particular aspect of servo motor forging presses is one of its most popular benefits.. Essentially, noise is greatly reduced compared to other forging processes.
• Control - Servo motor forging offers precision control of the forging process down to the smallest detail, which improves accuracy, enhances die life, increases productivity, and provides product stability.
• Environmental Protection - The servo motor forging process consumes less energy with fewer driving parts and requires less lubrication.

Pneumatic Forging Process

A pneumatic press generates force through compressed air or gas, which is directed into a cylinder attached to the ram. As the cylinder fills with air or gas, the pressure causes the ram to move downward. Once the force is no longer needed, the air or gas is expelled through an escape valve, causing the ram to release.

Upset Forging and Upsetters

Upset forging, also known as heading, involves a horizontal forging machine called an upsetter. This machine utilizes a ram that moves horizontally to apply pressure against the workpiece. The workpiece is secured between two die halves, and pressure is applied along its axis by a heading tool that deforms the end of the workpiece through metal displacement. The process uses two gripper and cavity dies: one stationary and the other attached to the moving die slide, along with a puncher mounted on the header slide.

During upset forging, the movable die slides toward the stationary die to grip and secure the workpiece. The punch or ram then moves forward, forcing the workpiece into the die cavities. Once the punch or ram retracts, the movable die opens to release the forged part. This cycle may be repeated multiple times until the desired shape is achieved.

Preheating the workpiece before upset forging is essential as it helps maintain the metal&#;s integrity and enhances its grain flow properties. This results in metal parts with improved tensile strength and durability due to the uninterrupted grain flow.

Upset forging is often used as an intermediate step in a multi-stage forging process. It is commonly employed to manufacture components such as bolts, screws, nuts, rivets, and flanged shafts.

Leading Manufacturers and Suppliers

Chapter Three &#; What are the advantages of using a forging press?

The forging press process is generally faster and more cost-effective compared to other methods. It results in a grain flow that enhances the strength of the final product. The diagram below illustrates the differences in grain flow among various methods: casting, machining, and forging. Casting typically exhibits no distinct grain flow, machining maintains a straight grain flow, while forging produces a grain flow that conforms to the shape of the piece.

The texture of the forged piece is continuous, which contributes to enhanced strength in the final product.

Advantages of the Forging Press Process

Strength-to-Weight Ratio

Throughout the forging process, the grain structure of the material is compressed, which reduces stress on corners and fillets, thereby increasing the overall strength of the piece.

Reduced Defects

Forging helps minimize metallurgical defects like porosity and alloy segregation, leading to less time required for machining the finished piece and better results during heat treatment.

Post Forging Treatments

Since forging eliminates voids and porosity, the pieces can be machined post-forging without compromising dimensional accuracy or quality. Tolerances are typically within 0.01 to 0.02 inches (0.25 to 0.5 mm).

Cost Savings

Forging offers cost savings through efficient raw material usage, decreased machining time, and the ability to reclaim die material.

Die Life Span

The longevity of a die depends on factors such as the materials being processed, the strength of the material, the precision of the required tolerances, and the complexity of the design.

Higher Productivity

Forging presses come in a broad range of tonnages, from a few hundred to several thousand tons, and can achieve working speeds of up to 40 or 50 parts per minute. The process typically completes parts in a single squeeze, although complex and intricate designs may slow down production. Forging presses are suitable for mass-producing a variety of components, including nuts, bolts, rivets, screws, brake levers, bearing races, valves, and many other parts.

Produces Complex Designs

In press forging, dies typically feature minimal draft, enabling the production of intricate and detailed shapes with high dimensional accuracy. Forging techniques can achieve deep protrusions, extending up to six times the material's thickness. By design, draft angles can be minimized or entirely removed to enhance precision.

Materials

Various ferrous metals, such as stainless steel, can be used in forging processes. Additionally, non-ferrous metals are particularly well-suited for press forging due to their desirable properties in shaping.

Process Control

In press forging, the speed, stroke length, and pressure of the die are automatically regulated to ensure precision and operational efficiency.

CNC Automation

The press forging process offers similar capabilities as other manufacturing techniques and can utilize CNC programming for design input, including automated blank feeding and removal of forged components.

S-T Intelligence Product Page

Plastic Deformation

Plastic deformation penetrates deeply into the workpiece, ensuring uniform deformation throughout the metal.

Operators

Like all manufacturing processes, safety is a critical consideration. A benefit of press forging is that it generally does not require specialized training for operators, apart from ensuring safety protocols are followed.

Mechanical Properties

Forged components exhibit enhanced toughness and strength due to their continuous grain structure. Press forging also improves the flexibility of the final products, making them more ductile. Additionally, forged parts are anisotropic, meaning their properties vary along different axes due to the grain alignment.

Consistency

Each forged component maintains consistent structural characteristics from the initial to the final part. The controlled and monitored production process ensures uniform composition and structure, minimizing variations in machinability and eliminating transfer distortion.

Chapter Four &#; Which metals are commonly used with forging presses?

Press forging can be applied to a wide variety of metals, although some are more suitable for the process than others. The metals commonly used include carbon steel, stainless steel, tool steel, aluminum, titanium, brass, and copper. High-temperature alloys containing cobalt, nickel, and molybdenum are also amenable to press forging. The selection of metal depends on the specific requirements of the final product, considering factors such as strength, durability, and weight.

Bar stock is selected based on its grain structure, mechanical properties, shape, dimensions, surface quality, and suitability for mass production.

Metals Used in a Forging Press

Steel

Steel must be heated to approximately °F (°C) to be suitable for press forging. This heating process enhances the steel's ductility and malleability, allowing it to be shaped effectively under pressure. The increased plasticity of the steel ensures that a billet can be formed permanently without the risk of cracking.

Aluminum

Aluminum is ideal for forging because it is lightweight, corrosion resistant, and durable. Forgings of aluminum are used in applications requiring performance and the ability to endure excessive stress. Aluminum has high thermal conductivity, design flexibility, and fracture toughness. It can be forged using open or closed dies and does not require preheating before being forged.

Titanium

Titanium boasts superior weight-to-strength and strength-to-density ratios, along with exceptional corrosion resistance. To enhance its inherent toughness and strength, titanium is heat-treated before being subjected to press forging.

Stainless Steel

Stainless steel, known for its corrosion resistance and remarkable strength, is versatile for forging into various shapes. Among its many grades, 304(L) and 316(L) are particularly used in press forging. Due to its strength, stainless steel demands higher pressures during forging and is processed at temperatures ranging from °F to °F (930°C to °C).

Brass

Once brass is trimmed to the desired lengths, it is heated to approximately °F (815°C) and then forged using either a closed or open die. Brass can be molded into various shapes and sizes, ranging from just a few ounces to several tons. Forged brass offers enhanced strength and durability.

Copper

Before forging, copper bars are heated to prepare them for shaping. Once heated, the bars are molded into their final form. Forged copper is known for its outstanding electrical and thermal conductivity. Copper forgings are categorized into high conductivity types and non-electrical grades, which are used for engineering purposes.

Magnesium

Magnesium is known for its low density while offering strength and stiffness that surpasses both steel and aluminum. However, it is more expensive and challenging to forge. The magnesium alloys most suitable for forging include AZ31B, AZ61A, AZ80A, ZK60A, M1A, and HM21A. Pure magnesium poses a risk of ignition, which is why it is typically alloyed with other metals to mitigate this issue.

Chapter Five &#; What are the disadvantages of a Forging Press?

The press forging process has many qualities that have made it an excellent means for producing high volumes of parts at low cost. Regardless of its wide use, there are drawbacks, limitations, and disadvantages to the process.

Disadvantages of Press Forging

Cost

Cost is a significant consideration in press forging. The machinery used for this process is large and must be robust to generate the necessary force. The tools and dies used must be custom-made from specific metals.

Complex Parts

Press forging is not suitable for producing highly intricate parts and designs. While it can handle components with complex external shapes, it struggles with parts requiring internal cavities and detailed features.

Types of Parts

Only parts that can be shaped by pressing two dies together can be manufactured. Delicate features, overhangs, and special additions are not feasible with this method.

Dies

Forging press dies are costly and challenging to produce, especially for complex parts. They are crafted from a specific steel type, which must be heat-treated, roughly machined, and finely finished.

Amount of Force

Pressing a part in a forging press requires immense pressure, necessitating large and costly equipment.

Heated Metals

If a metal needs to be heated before press forging, additional finishing steps are required after the process.

Size

Press forging is limited to producing parts of specific sizes, which excludes large-scale designs.

Metals

The types of metals suitable for press forging are restricted. Cast iron, chromium, and tungsten cannot be forged using this method due to their brittleness.

Defects

Despite eliminating shrinkage and porosity, press forging can still result in defects such as laps, piping, and die failures in the final product.

Tolerances

Forging presses cannot achieve millimeter-level tolerances.

Residual Stress

Metals that require heating before pressing can develop residual stress if not cooled properly after the process.

Scale Pits

Scale pits occur when the surface to be forged is inadequately cleaned, particularly in open environment forgings.

Flakes

Flakes are internal cracks that appear during the cooling phase after heating and pressing, weakening the final product.

Time Consumption

Press forging applies pressure gradually, with the die remaining in contact with the workpiece for an extended period, which slows down production.

Chapter Six &#; What parts are produced by a forging press?

Forging presses play a crucial role in the manufacturing processes across various industries, including automotive, aerospace, agricultural machinery, oilfield components, tools and hardware, and military ordnance.

Automotive Parts

In automobiles, press forged components are used at locations subjected to shock and stress. A single car or truck may contain more than 200 press forged parts. Some examples are illustrated in the diagram below.

Aerospace Parts

Both ferrous and nonferrous forgings are utilized in helicopters, piston-engine planes, commercial airliners, and supersonic military jets. Aircraft are engineered with press forged components and may include over 400 distinct forged parts. Examples are shown in the diagram below.

Tractors and Earthmovers Parts

Forged components used in farm tractors and earthmovers include engine and transmission parts, gears, sprockets, levers, shafts, spindles, ball joints, wheel hubs, rollers, yokes, axle beams, bearing holders, and links.

Tank Parts

There are more than five hundred forged components in tanks.

Oil Platform Valves and Fittings

Forging press components are crucial in the construction of oil platforms because of their durability, absence of porosity, and capacity to endure high-pressure environments.

Chapter Seven &#; What are the safety requirements for operating a forging press?

The Occupational Safety and Health Administration (OSHA) has established guidelines and standards that manufacturers must adhere to for the safe operation of forging presses.

OSHA's regulations for operating forging presses are detailed in standard 29 CFR Part .

Required Inspections

• Clutch
• Brake
• Linkages
• Counterbalances
• Air lines
• Worn or damaged parts

Important Safety Considerations

1. Electrical: Presses must have a disconnect switch, motor starter, and a transformer for reducing voltage
2. Covers: Shafts, crankshafts, pulleys, sprockets, rolls, flywheels, gears, and couplings must be covered.
3. Side Barriers: Side barriers include light curtains to prevent standing near the point of operation.
4. Guards: If light curtains are not being used between the operator and point of operation, then guards should be installed.
5. Danger Signs: Warning signs should be mounted on the device and must be clearly visible.
6. Hand Tools: Hand tools should be used when feeding or retrieving pieces from the equipment.
7. Mirrors: Mirrors should be mounted on the sides and back of the machine.
8. Two Hand Controls: Two hand controls are necessary for single stroke devices.
9. Pullback or Pullout Devices: Pullbacks, attached to the operator&#;s hands, pull the operator&#;s hands away from the machine when it begins its stroke.
10. Restraints: Restraints operate on the same principle as pullbacks and are adjusted so the operator can never reach the point of operation.
11. Gates: Gates can be type A or type B. A gates are used in full revolution presses, while B gates are used in partial revolution presses. A gates must be closed before press operation begins and must remain closed. B gates protect the operator on the down stroke.

Conclusion

• The forging press process uses a vertical ram to apply gradual, controlled pressure to a die holding a workpiece.
• There are several methods for creating force for a forging press, which include mechanical, hydraulic, servo, and pneumatic.
• The process of a forging press is quicker and less expensive than other production methods.
• Regardless of the wide use of press forging, there are drawbacks, limitations, and disadvantages to the process.
• Forging presses are an essential part of the manufacturing processes of several industries, which include automotive, aerospace, agricultural equipment, oilfield parts, tools and hardware, and military ordnance.

Leading Manufacturers and Suppliers

Press forging is a variation on the forging process. Rather than the metal workpiece being &#;hit&#; with a single or multiple blow, the forming process is more akin to the kneading of bread. A high-power press is used to squeeze the metal into a new shape or section size. Press forging is most commonly used as the first shaping process of large, cast ingots to close-up any internal voids and make a bar more suitable for further forging. After press forging, the metal workpiece will normally be returned to a reheat furnace, to bring it up to temperature ready for hammer or die forging.

What are the advantages of press forging?

The biggest advantage of press forging lies in its ability to deform the workpiece through its section thickness. Hammer forging will only affect the surface of the workpiece whereas press forging will change the shape and interior of the workpiece too. Press forging is also more controlled than hammer forging and provides a more uniform strain rate. As a slower process, there is a greater degree of control possible.

Here are some other advantages of press forging &#;

• Press forging offers greater accuracy in terms of tolerances within 0.01 to 0.02 inch with higher productivity than drop forging
• Dies used for press forging have less draft, which means more complicated shapes can be forged with increased dimensional accuracy
• In press forging, the speed, pressure and travel of the die are automatically controlled
• Through the mechanism of blank feeding and forging removal, there is the possibility of process automation
• This operation is completed in a single squeezing action which saves time
• Press capacity ranges from 500 to tonnes with the number of working strokes per minute as high as 40 or 50, which means 40-50 parts can be produced per minute
• Due to the fast delivery time, press forging is also suitable for mass production of nuts, bolts, rivets, screws, brake leavers, bearing races and valves

Got any more questions? Get in Touch

 If you have any more questions about sourcing forged components in austenitic or duplex stainless steels, nickel alloys or high-performance copper alloys, please contact us today. A member of our team will be more than happy to help and can also advise you on the best option for your application.

The company is the world’s best Servo Cold Forging Press supplier. We are your one-stop shop for all needs. Our staff are highly-specialized and will help you find the product you need.