Drop Forging [Procedure + Video]

DROP FORGING PROCEDURE

1. DEFINITION

Drop forging or also drop forming comes from the group of forming processes, more precisely massive forming processes.

The tool – the die – contains the molded part to be manufactured as a negative. The dies are moved against each other with great force and the material is worked into the desired shape.

The excess material is pushed into the so-called ridge. The deburring, i.e. the removal of the excess material, is carried out with the help of other tools, which act like a stamp.

The forgings convince with a homogeneous, dense fiber flow, which has neither pores nor other cavities.

Most often, die forming takes place at workpiece temperatures above the recrystallization temperature, which is why it is also referred to as hot forming.

In principle, all metals that can be kneaded after heating are suitable for drop forging. Most drop forgings are made from steel.

2. AN OVERVIEW OF DROP FORGING

1. Preforming

First, the blank is separated from the semi-finished product and brought to the workpiece temperature.

With the help of rollers, presses or an air hammer, the heated blank is preformed if necessary.

2. Forging process

In the next step of the forging process, the blank is placed in a closed die.

The upper and lower dies contain the contour of the desired forging as a negative and press the blank into the appropriate shape with several strokes.

Excess material is pushed into the ridge.

3. Deburring

With the help of special tools, deburring is carried out on another press.

4. Tempering of drop forgings

This is followed by the final tempering (heat treatment) of the forgings in furnaces.

5. Descaling

The scale layer created is now mechanically removed from the forging.

6. Final inspection

After the forging process has been completed, all precision molded parts in metal forming technology are subjected to a comprehensive visual inspection.

The entire scope of all criteria and measures of quality control is coordinated in a functional manner depending on customer requirements.

3. VIDEO: PROCESS FLOW IN DROP FORGING

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4. ORIGIN OF THE FORMING PROCESS

The forging process has been taking place since 1,500 BC. Chr.. At that time, the blank was placed in the die during die forging and hammered into shape. Although the forming technology was continuously developed in the following years, the production of modern drop forging tools only succeeded in England towards the end of the 19th century.

This progress was significantly favored by the development of the steam hammer, which made it possible to forge large parts. With the advancement of the 20th century, the achievable accuracy in drop forging became ever higher. Modern developments also aim at a higher level of automation in the forging process.

Drop forging is of particular importance in the processing of metals. The forming technology is suitable for the production of small forged products such as screws and bolts as well as for the production of large drop forgings for automobiles and airplanes. This means that the mass of the molded parts produced by forging processes ranges from a few grams to well over a ton.

In Germany, about 2/3 of the forging technology can be assigned to the total amount of forged parts produced. Half of the forged products created are supplied to the automotive industry.

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REFERENCES

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