Forging is at the core of the B&G manufacturing process, allowing us to produce various and complex machined products for our diverse range of clients in the markets we serve. Our clients look for parts and instruments which can withstand extreme conditions, have complex geometries, and meet strict quality standards. Our forging process is one of the ways we achieve this, and the science of it comes down to three factors; heat, pressure, and precision.
Forging Heat
The primary function of heat in forging is to make the metal more malleable and easier to shape. When metal is heated to a specific temperature, typically between 950°C–1250°C., depending on the desired properties of the finished product and the type of metal, it becomes more ductile and less prone to cracking or breaking. This temperature is critical to the task at hand because it helps to remove any impurities in the metal, which can affect the strength and durability of the finished product.
Heat also helps in reducing the forces required to shape the metal. When heated, the metal becomes more elastic, allowing it to be deformed more easily. This reduces the force needed to shape the metal, resulting in a more efficient and cost-effective operation.
Heat also plays a role in controlling the microstructure of the metal. By heating the metal to specific temperatures and then cooling it in a controlled manner, manufacturers can control the grain size, shape, and orientation of the metal. This results in a more uniform and predictable structure, which can improve the finished product’s strength, toughness, and fatigue resistance.
Pressure
When heated to a specific temperature, metal becomes more malleable and easier to shape. However, it still requires significant force to deform the metal into the desired shape. Pressure is applied to the heated metal to shape and bend it into the desired form. There are several ways in which pressure is applied:
- Hammer Forging: Here, the metal is placed on
a die and repeatedly struck with a hammer to shape it into
the desired form.
- Press Forging: In this case, the metal is placed between
two dies and then compressed using a hydraulic press to
shape it into the desired form. - Roll Forging: Here, the metal is placed between two
rollers and then compressed to shape it into the desired
form. - Upset Forging: Here, the metal is placed between
two dies and then compressed to increase its thickness and
shape it into the desired form.
The amount of pressure applied to the metal must be carefully controlled to ensure it is not overworked, which can cause it to crack or weaken. The pressure is typically applied in a series of controlled steps, with each step slightly increasing the deformation of the metal.
Precision
The role of precision in forging is to ensure that the end product matches the desired specifications and requirements. It must be carefully controlled to ensure the metal is shaped into the desired form and required standards. It calls for a combination of skill, experience, and technology to monitor and control. At B&G, we achieve precision through a combination of factors, including:
- Die Design: The design of the forging die is critical to
achieving precision. The die must be
designed to ensure that the metal flows into the desired
shape and that the final product meets the required
tolerances. - Material Selection: Selecting the appropriate material for the
forging die is also critical to achieving precision in the
process. The die material must withstand the high pressures
and temperatures of the forging process while maintaining its
dimensional stability. - Temperature Control: Temperature control is essential.
- The temperature of the metal must be
carefully controlled to ensure that it is within the appropriate
range for the desired properties and consistent throughout
the process. - Inspection and Testing: Precision forging requires careful
inspection and testing of the final product to ensure it meets
the desired specifications and requirements. This may
include dimensional measurement, visual inspection, and
non-destructive testing to ensure the product is free from
defects and meets the required quality standards.
Overall, our forging process is critical in manufacturing machine and device parts for various industries. By applying heat, pressure, and precision, our skilled operators can produce high-quality parts that are strong, accurate, durable, and reliable. The process also enables the creation of complex shapes and
designs, making it an essential part of modern manufacturing. Contact us today to find out more.
Hatfield
