Forging is the process of forming material into a solid state, typically by heating the metal first to make it malleable and then hammering or pressing it to create a specific shape. Machining is a term that is typically a computerized process that passes a piece of metal into the machining tool.
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When it comes to manufacturing metal parts, it is crucial to consider all the different variables that are needed to ensure that you are making the right decision. Each manufacturing process is a viable option, and so it all depends on so many factors – especially where and what it is for, the amount, and its total cost.
Forging is the process of forming material into a solid state, typically by heating the metal first to make it malleable and then hammering or pressing it to create a specific shape. Machining is a term that is typically a computerized process that passes a piece of metal into the machining tool. It is used to remove excess metal from raw materials. Most forging and casting processes result in dimensions and surface conditions that will still require machining to achieve the desired dimension and shape.
Pros of Machining
Machining is convenient for producing pieces of complicated and acute-angled shapes. It is suitable and cost-effective for one-time production and for those who are not aiming for mass production output. Some forgings also use machines for surface finishes to cast molds for their forging presses due to pre-program accuracy.
Pros of Forging
- Forging is the perfect option if you need to make thousands of replicas of the same molded piece of metal. It offers uniformity of composition and structure. Forging results in metallurgical recrystallization and grain. The tight grain structure of forging offers great wear resistance without the need to make products harder than they are.
- Ask yourself how strong and detailed you need your product to be. While machining is probably the most useful alternative in a wider variety of situations, forging is the way to go if you're looking for a stronger and tactile production.
Why Choose Forgings?
Forging is defined as the process of heating, deforming, and finishing a piece of metal. Forgings are made by forcing materials into customized shapes either by the force of a falling ram upon an anvil or by a die press enclosing a piece of metal and squeeze-forming the part. Due to the realigning of the grains of metal when heated and deformed, forgings can withstand extreme pressure and maintain structural integrity under stress. Once produced, forgings have a broad range of uses across a variety of industries ranging from heavy trucks, medical supplies, automotive parts, to aerospace.
The forging process creates parts that are stronger than those manufactured by any other metalworking process. Forging takes advantage of the metal's natural grain flow, shaping the grain flow to conform to the contours of each part's unique geometry. This grain flow contouring is lost when cutting through the grain by machining it and is also lost when casting parts. Forging offers a single piece versus a welded unit, as the weld quality can be hard to replicate without additional inspection.
Forgings can be nearly any shape, which reduces the need for joining multiple pieces. Reducing the joint can improve the overall strength of the unit as the forging does not need to be welded or otherwise fastened together.
Forgings are stronger. Castings do not have strengthening benefits yielded by hot and cold forgings. Forging surpasses casting in predictable strength properties and produces superior simultaneously more ductile and resistant pieces with uniform quality assured across the production run.
Forging refines defects from cast ingots or continuous cast bar. A casting is defined as having neither grain flow nor directional strength and the casting process cannot prevent the formation of certain metallurgical defects. Pre-working forge stock produces a grain flow oriented in directions requiring maximum strength. Dendritic structures, alloy segregations, and similar imperfections are also refined in forging.
Forgings are consistently more reliable and often less costly over time compared to castings. Casting defects occur in a variety of forms. Because hot working refines grain patterns and imparts high strength, ductility, and resistance to each forged piece they are also more durable. Also, they are manufactured without the added costs for tighter process controls and inspections that are required for castings.
Forgings also offer a better response to heat treatment. Castings require close control of melting and cooling processes because alloy segregation may occur. This results in a non-uniform heat treatment response that can affect the straightness of finished parts. Forgings respond more predictably to heat treatment and offer better dimensional stability.
Production of forgings allows for flexible, cost-effective adaption to market demand. Some castings, such as special performance castings, require expensive materials and process controls, and longer lead times. Open-die and ring rolling are examples of forging processes that adapt to various production run lengths and enable shortened lead times.
Forgings offer production economies and material savings. Welded fabrications are more costly in high-volume production runs. In fact, fabricated parts are a traditional source of forging conversions as production volume increases. Initial tooling costs for forging can be absorbed by production volume and material savings. Forgings' production economics lower labor costs, scrap and rework reductions through reduced inspection costs.
Forgings are stronger. Welded structures are not generally free of porosity. Any strength benefit gained from welding or fastening standard rolled products can be lost by poor welding or joining practice. The grain orientation achieved in forging makes stronger parts.
Forgings also offer cost-effective designs. Defined as a multiple-component welded assembly cannot match the cost-savings gained from a properly designed, one-piece forging. Such part consolidations can result in considerable cost savings. In addition, weldments require costly inspection procedures, especially for highly stressed components. Forgings do not.
Forgings offer more consistent, better metallurgical properties. Selective heating and non-uniform cooling that occur in welding can yield undesirable metallurgical properties such as inconsistent grain structure. When in use, a welded seam may act as a notch that can contribute to part failure. Forgings have no internal voids that might cause unexpected failure under stress or impact.
Forgings offer simplified production. Welding and mechanical fastening require careful selection of joining materials, fastening types and sizes, and close monitoring of tightening practices both of which increase production costs. Forging simplifies production and ensures better quality and consistency.
Key Things to Know Before Choosing Custom Forgings
There's a huge reason why custom forgings hold such a prestigious place in the manufacturing industry. For those who unfamiliar, custom forgings process are custom metal parts uniquely shaped by manipulating heated metal under immense pressure.
Design Considerations for Custom Forgings
The beauty of custom forgings lies in their design flexibility. Unlike mass-produced parts, custom forgings can be tailored to your exact specifications. This freedom allows you to bring even the most intricate designs to life. However, it's important to remember that there are some limitations to consider during the design phase.
Material Selection for Custom Forgings
The next crucial step is choosing the right material for your custom forgings. Different metals offer unique properties, making them suitable for various applications. For instance, high-strength steel might be ideal for components needing exceptional durability, while aluminum could be a better choice for lightweight applications. Consulting a material expert during this stage will ensure you select the perfect material to meet your project's functionality needs.
Understanding the Machining Needs of Custom Forgings
While custom forgings offer a high degree of design freedom, they might still require some level of machining after the forging process. This additional step refines the forged part to its final dimensions and tolerances. The extent of machine needed depends on the complexity of your design and the desired level of precision. During the planning phase, discussing your project requirements with your forging partner will help determine the optimal balance between forging and machining for cost-effectiveness and precision.
Budgeting for Custom Forgings
When it comes to custom forgings, it's no secret that they can involve a higher upfront cost compared to off-the-shelf parts. However, the long-term benefits often outweigh the initial investment. Custom forgings can provide superior strength, improved performance, and potentially lighter weight compared to machined parts. This translates to parts that last longer, require less maintenance, and can even enhance the overall efficiency of your project.
Lead Time Considerations for Custom Forgings
Due to the custom nature of forgings, there is typically a longer lead time involved compared to readily available parts. This is because custom tooling may need to be created to precisely shape the metal during the forging process.
Aesthetics of Custom Forgings
Beyond functionality, custom forgings can also elevate the aesthetics of your project. The inherent beauty of forged metal, with its smooth surfaces and defined features, can add a touch of sophistication to any design. This makes custom forgings ideal for architectural components, high-end machinery, and other applications where visual appeal is equally important as functionality.
It is always best to employ design for manufacturing (DfM) principles: design parts based on the manufacturing process that will be used.
Parts for machining need to be designed differently to, for example, parts for 3D printing.
Fortunately, machined parts are not especially difficult to design — just as long as certain rules are followed. These rules are outlined below.
Undercuts
- Undercuts are cuts in the workpiece that cannot be executed using standard cutting tools (because a section of the part is obstructing it). They require special cutting tools — T-shaped ones, for example — and special machining design considerations.
- Since cutting tools are made in standard sizes, undercut dimensions should be in whole millimeters to match the tool. (For standard cuts this doesn't matter, since the tool can move back and forth in tiny increments.)
- Undercut width can range from 3–40 mm, depending on the cutting tool, with undercut depth up to twice the width.
- If undercuts can be avoided altogether, the machined parts can be made much faster and with less effort.
Wall thickness
- Contrary to molded parts, which deform if walls are too thick, machined parts cannot handle especially thin walls. Designers should avoid thin walls, or use a process like injection molding if thin walls are integral to the design.
- When machining, wall thicknesses should be a minimum of 0.8 mm (metal) or 1.5 mm (plastic).
Protrusions
- As with thin walls, tall protruding sections are difficult to machine, as the vibrations of the cutting tool can damage the section or result in lower accuracy.
- A protruding feature should have a height no greater than four times its width.
Cavities, holes, and threads
- When designing machined parts, it is important to remember that holes and cavities are dependent on the cutting tools.
- Cavities and pockets can be machined into a part to a depth of four times the cavity width. Deeper cavities will necessarily end up with fillets — rounded rather than sharp edges — because of the required cutting tool diameter.
- Holes, which are made with drill bits, should also have a depth of no more than four times the drill bit width. And hole diameters should, where possible, correspond to standard drill bit sizes.
- Threads, used to incorporate fasteners like screws, do not need to be deeper than three times the diameter.
Scale
CNC machined parts are limited in size because they are fabricated within the build envelope of the machine. Milled parts should measure no more than 400 x 250 x 150 mm; turned parts should measure no more than Ø 500 mm x 1000 mm.
Machined part materials
- Machined parts can be made from many different materials, including metals and plastics.
- However, some materials are easier to machine than others. Very hard materials are difficult to penetrate with a cutting tool and may cause the tool to vibrate more (consequently reducing quality). Very soft materials and materials with a very low melting point may deform upon contact with the cutting tool.
- The most common machined part materials are listed below. Other materials can also be machined upon request to the manufacturer.
- Metal: Aluminum, Steel, Stainless Steel (17-4, Inconel 625 & 718), Magnesium, Titanium, Zinc, Brass, Bronze, Copper.
- Plastic: ABS, PC, ABS+PC, PP, PS, POM, PMMA (Acrylic), PAGF30, PCGF30, Teflon, DHPE, HDPE, PPS, PEEK. (Less common: PA GF50, PPS GF50.)
Machined part surface finishes
Machined parts can be treated after machining in order to alter their surface texture and appearance. Finishes can be either functional or cosmetic.
As-machined: No surface finish added. This is suitable for many internal, non-cosmetic functional components.
Bead blasted: The bead blasting process involves firing abrasive media at the machined part, leaving it with a matte appearance. The process can be adjusted to give a specific level of roughness. It may not be suitable for fine features, since bead blasting removes material and therefore affects the geometry of the machined parts.
Anodized: The electrolytical passivation process of anodization is suitable for aluminum machined parts, creating a scratch-resistant, colorful coating. Type II anodization creates a corrosion-resistant finish; Type III is thicker and creates wear resistance in addition to corrosion resistance.
Powder coated: During the power coating process, powdered paint (in the color of the designer's choice) is sprayed onto the machined part, which is then baked in an oven. This creates a strong, wear-resistant, and corrosion-resistant layer that is more durable than standard paint coatings.
Our Factory
Xian Huan-Tai Technology and Development Co.,Ltd was formed in 1995 to supply Aluminum dross press and steel & iron castings to the aluminum industries; Also supply mechanical products（parts) to the automotive industry, railways, oil exploration, mining, and construction for more than 27 years. Our dross press was designed by a guru in the aluminum industry for more than 40 years of experience, who has more than 250 sets of dross press installation experience. Our dross pan, drain pan, skim pot, slag bin, slag pan, sow molds, and ingot molds are made of durable castings, the material is proprietary steel.
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