Manufacturing and Production

Forging and Hot Metal Forming

Forging produces components with a grain flow that follows the shape, which is why forged parts survive loads that castings and machined bar do not, and why a poorly designed forging throws that advantage away. This course covers keeping it. Delegates work through metal flow under load, the forging temperature range and the consequences of working outside it at either end. Open die, closed die and upset forging are covered with the products and tolerances each gives. Die design is addressed, including flash, gutter, draft and the fillet radii that prevent laps. Preform and blocker design follow, since most forging faults originate in the stage before the finish impression. Heating practice is covered, including scale, decarburisation and overheating. Press and hammer selection is addressed. Trimming, straightening and post forge heat treatment follow. Defects are diagnosed: laps, cold shuts, underfill and flow line disruption. The course closes on die wear, on lubrication and on forging tolerance expectations.