Forging Equipments
Forging equipment is essential for shaping metal by applying compressive forces. The primary types of equipment include forging hammers, presses, and upsetting machines.
Forging hammers (like drop hammers and power hammers) deliver high-impact blows to shape metal and are often used in closed-die forging.
Forging presses apply steady pressure and are ideal for open-die and precision forging, offering better control over the deformation process.
Upsetting machines increase the diameter of metal parts and are commonly used for bolts and shafts.
Heating Equipments
Heating equipment in forging is used to raise the temperature of metal workpieces to make them malleable for deformation. Proper heating is crucial to reduce resistance to deformation, prevent cracking, and improve material flow.
The most commonly used heating equipment includes:
Forging Furnaces: These can be gas-fired, oil-fired, or electric, and are used to uniformly heat metal billets or ingots to forging temperatures (typically between 950°C and 1250°C for steel).
Induction Heaters: Use electromagnetic fields to rapidly and efficiently heat metal parts. They provide precise, localized heating and are widely used in automated and high-volume forging operations.
Tooling
- Forging Dies
- Punches and Drifts
- Bolsters and Die Holders
Forging Dies
Open-Die Dies: Simple flat or contoured dies used to shape large, unconfined metal workpieces.
Closed-Die (Impression) Dies: Precisely shaped dies that fully enclose the metal, forming it into final or near-net shapes.
Insert Dies: Replaceable die inserts fitted into larger die blocks, designed to reduce wear and lower tooling costs.
Mandrels and Plugs
These are used to support and shape hollow parts such as rings and tubes during forging operations.Punches and Drifts
Punches: Used to create holes or indentations in the workpiece.
Drifts: Employed to expand or finish holes to the desired dimensions.
Bolsters and Die Holders
These components provide structural support and maintain the proper alignment of dies within forging machines.Lubricants and Die Coatings
Applied to reduce friction and tool wear, facilitate smoother metal flow, and enhance die life and product quality.
Handling Equipments
Handling equipment in forging is used to safely move, position, and hold hot metal workpieces during the forging process. These tools are essential for maintaining operator safety, improving efficiency, and ensuring accurate forging operations.
Tongs
Manually operated tools used to grip and hold hot metal pieces. They come in various shapes and sizes depending on the workpiece geometry.Manipulators
Mechanized or hydraulic machines that can lift, rotate, and position heavy or hot workpieces with precision. They are commonly used in large-scale or automated forging setups.Lifting Cranes and Hoists
Used to transport large billets or forged components within the forging facility. Overhead cranes are especially common in heavy forging operations.Roller Tables and Conveyors
Facilitate the movement of hot metal between different stages of the forging process, such as from the furnace to the hammer or press.Robotic Arms
Automated arms used in high-volume production for precise and repeatable handling of workpieces, improving both speed and safety.
Cooling System
In forging, cooling systems play a crucial role in managing the temperature of tools, dies, and sometimes even the forged parts themselves. Proper cooling is essential—it helps extend the life of the dies, keeps the equipment from overheating, and ensures that the final product maintains its shape and quality.
Water Cooling Systems
These systems use built-in channels within dies or tools to circulate water and carry away excess heat. They’re especially common in closed-die forging, where temperature control is critical for precision and consistency.
Air and Air-Mist Cooling
Instead of water, some setups use compressed air or a mist made from air and water to cool down hot surfaces. This method is useful when direct water contact might cause damage or is otherwise not suitable.
Cooling Jackets
These are external covers that circulate cooling fluid around components like press columns or large tools. They help prevent overheating, especially during continuous or heavy-duty forging operations.