Forging is a kind of manufacturing process used to produce metal parts. These parts are then further used in building large and complex machines. Many industries and companies have their idea for producing their desired metal part and components. It can be any company. However, the crux of the service lies in the quality of the forging process employed as well as the equipment used while producing the required metal components. We have the need, we have the setup but we do not know where to go to get the quality forged metal parts. The answer to this is simple. Forgewell, one of India’s foremost forging companies operating from Faridabad, is a dedicated enterprise that specializes in creating some of the best-forged components in the country. In this article, we will learn a lot about forging and its method, and why you must Forgewell as the best Forging Company in Faridabad.

What is Forging?

Forging is a manufacturing process. More precisely, it is a metalworking process. Forging is a process that involves shaping metal. One can forge material by applying localized compressive forces using any of the following techniques:

• Hammering
• Pressing
• Rolling

In forging, manufacturers will heat the metal to a temperature to make it more malleable while maintaining its solidity.

To know more about forging, refer to the official website of Forgewell Industries, one of the premium Forging Companies in Faridabad.

How is Forging Different from Casting?

In summary, forging involves shaping metal through compressive forces at elevated temperatures, resulting in parts with superior mechanical properties, while casting involves pouring molten metal into molds to produce parts with complex shapes at lower costs and higher production rates.

A Bit About Forging

Experts define forging as a process of shaping metal using localized compressive forces through the use of various techniques. The metal is pre-heated to a better malleable temperature while maintaining the solidity of the metal.

There are various types of forging, like open-die forging. In this type of forging, metal is hammered and then pressed between two flat dies. This allows the metal to flow and take the shape of the mold dies. In closed-die forging, one can enclose metal within dies or a cavity in the shape of the desired part, where the dies apply pressure to shape the metal into the form. Roll Forging is simple as the metal will be shaped by passing it between two or more rotating rollers.

While such elaborate forging options, the process offers various advantages, like producing parts with better mechanical properties, like the following:

• Strength
• Toughness
• Agility
• Fatigue Resistance

There is also a grain structure method, in which you can align the metal along the part’s shape to enhance its mechanical properties, which makes the item suitable for producing parts. The produced parts will have high strength-to-weight ratios along with structural integrity.

With such advantages, forging has found various applications in the Forging Industry in India, like in the manufacture of automotive components, aerospace parts, industrial machinery, and hand tools. One can build it like crankshafts, connecting rods, landing gear, turbine blades, gears, shafts, wrenches, hammers, and more, using forging.

To know more about forging, refer to the official website of Forgewell Industries, one of the premium Forging Companies in Faridabad and India.

About Casting & How they are different?

Talking Casting, it is a process in which metal is poured in a molten state into a mold cavity, which upon solidification takes the shape of its mold. The mold material can be many, like sand, metal, or even ceramic materials.

Taking about its types, Casting can be done in multiple ways, like Sand Casting. In this casting method, one uses sand molds to create the shape. There is also investment casting, where we create a wax pattern, encased in a ceramic shell. Later, the wax is melted out, leaving the cavity filled with metal. In the die-casting method, one can forge the molten metal into a steel mold cavity by applying high pressure.

Casting too has several benefits as a manufacturing process. One can produce complex metal shapes with intricate details as well as thin walls using Casting. Casting is a suitable method for mass production, as it has relatively cheaper tooling costs, which can further boost the production rates. Manufacturers also use versatile processes employing a wide range of metals and alloys.

Casting has found many applications in the manufacturing sectors, like automotive manufacturing, construction, jewelry making, and Sculpture and art casting. Items that can be cast with due process can be engine blocks, cylinder heads, structural components, fittings, rings, pendants, etc.

Why do use Forging as a Manufacturing method?

If you employ forging as a production process, then you will at multiple production value advantages, like better mechanical properties. Forged parts typically exhibit better mechanical properties. Forging imparts strength, toughness, and fatigue resistance to the production items. Forging employs a grain structure to align the metal with the shape of the intended part.

Forging also imparts structural integrity to the product. In forging, compressive forces are applied help to refine the metal’s grain structure. This improves the structural integrity as well as defect resistance of the item. A forged part has a high Strength-to-Weight ratio, which makes it suitable for strength and durability applications. Many Sectors and Industries use forging as a production process, such as automotive manufacturing, aerospace, industrial machinery, etc., where high-performance components with exceptional mechanical properties are favored, along with immense structural integrity. To know more about forging, refer to the official website of the Forgewell, one of the top Forging Companies in Faridabad.

What does a typical Forging Process look like?

The forging process is comprised of a series of steps, beginning from initial metal preparation to the final shaping of the forged component. First, you will select the material.

Material Selection for forging procedure

Selecting the appropriate metal or alloy is paramount for the desired production. One can use common materials such as steel, aluminum, copper, or even titanium in forging. Then the heating part begins. The metal is heated to a temperature to make it malleable in trace solidity. The set temperature for forging depends on the material as well as its composition. The beating begins in a furnace, which ensures uniform temperature throughout the metal piece.

Forging Operation; Casting the Dies

To begin the forging operation, we have to first choose the forging method. In case, you choose closed-die forging, then the metal tooling is prepared as per the intended shape of the final item. Thereafter, we will place the heated metal as a billet or workpiece. We will place it on the lower die. It can be an anvil also. Later, we will apply compressive forces to the metal, by using any of the following methods, which will render the metal to deform and take the die shape:

• Hammer
• Press
• Rolling Mill

If the component is built to be a large complex part, you need to reheat the metal during forging. This will maintain the required temperature for supposed malleability.

Trimming off the Excess from the Forged Component

After concluding the forging operation, you can trim off the excess material as well as flash from the forged part. Use a cutting tool or trimming dies for this incision. You can further polish the part with additional finishing processes like machining, grinding, heat treatment, etc. Each such process can aid you in achieving the desired surface finish of the component with precise dimensional accuracy.

Check for Defects, if any

You can check the forged part for defects. In component production, dimensional accuracy, and stable mechanical properties matter. One can also opt for non-destructive testing methods such as the following to detect internal defects

• Ultrasonic Testing
• Magnetic Particle Inspection

For the final inspection, one must observe the quality control. The finished parts must undergo a final inspection to check the measure of required specifications as well as quality standards. Talking about packaging and shipping, one must pack the finished forged parts as per their customer’s requirements and thereafter ship them to the destination.

One must remember that throughout the forging process, you must observe strict quality control measures to ensure the integrity as well as the intended performance of the final forged component. You can control the temperature, compressive force, shaping molds, etc., to produce high-quality forged components. Each such part will have superior mechanical properties as well as heightened structural integrity.

Types of Forging

There are majorly three types of forging methods, namely, Open, Closed, and Roll Forging. 

Open-Die Forging

The open-die forging method allows the metal to be placed between flat dies. One can also hammer or press the items to give them shape. The shaped metal is then flowed and shaped in the die form. This forging method is used for forging large components or components with complex shapes.

Closed-Die Forging

Closed Die forging is also known as Impression-Die forging. In this method, we enclose the metal within the dies. Such dies have a cavity in the shape of the desired component form. The die is then pressed from all sides to shape the metal into the form. This forging method is employed for producing high-volume forged parts, each with tight tolerances.

Roll Forging

Roll forging employs metal to be shaped by passing it between rotating rollers to produce long and cylindrical parts such as shafts and bars. There are other forms of forging methods as well, such as Hot & Cold Forging, Drop Forging, Press Forging, Upset Forging, Isothermal Forging, etc.

To know more about the forging type in great detail refer to the official website of the Forgewell, one of the best forging companies in Faridabad.

Equipment used for Forging Procedures

Each forging method in operations requires specialized equipment. This equipment is applied to the compressive forces to shape the metal into the desired form. Majorly, Manufacturing Industries use the following equipment in their forging procedures:

• Forging Presses, such as Mechanical and Hydraulic Presses, as well as Screw Presses
• Forging Hammers, such as Steam Hammers, Drop Hammers, and Power Hammers
• Heating Equipment, such as a Furnace or an Induction Heating Systems
• Tooling and Dies of all forms and casts
• Trimming Equipment
• Finishing Equipment
• Material Handling Equipment

Forgewell Limited: the Best Forging Company in Faridabad

Forgewell Limited is one of the top Forging Companies in Faridabad. We began operations with one drop hammer. But with hard work and determination, we build ourselves into a family-managed company. We are a medium-sized structure company founded in 1978. With such progressive years, we have always acted with the entire focus on our customers. We serve our employees for the better. Later, we accepted the oncoming corporate culture to guarantee our customers a level of willingness. We strive for innovation in our production quality.

Forgewell Company has multiple production lines with Drop Hammers as well as Ring Rolling and Heat Treatment. We also have an in-house CNC and VMC Machining. We are also a pioneer in using Deep Hole Gun Drilling. Forgewell is known in the market for its timely delivery as well as reliable services. We deliver exceptional quality products, with which we have won extensive trust from our clients.

Forgewell is one of the biggest Forging Companies in India!