Press Forging

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1.What is press forging process

Youlin® Press forging can be defined as the forming process of placing metal between two dies by applying mechanical or hydraulic pressure. Press forging is usually done on a forging press, a machine that exerts a gradual pressure on a forging die. The metal shape is usually formed by a single punch stroke for each die station. Press forging can adopt hot forging or cold forging process. It is suitable for high volume productivity of forgings.

2.Drop Forging vs Press Forging

Youlin® Press forging is similar to drop forging except that it uses continuous extrusion pressure applied by a hydraulic press. This process increases the length of the workpiece and reduces the section of the workpiece.
Drop forging is when half of the die is dropped from a height onto the other half of the die, which will contain the hot metal workpiece to be formed. Drop forging is more suitable for mass production. Press forming is instead of dropping half the die onto the other half the two halves are put together and pushed together under a large pressure (up to about 10000 tons) forming the object. The difference is that drop forming leaves the center of the metal not so hard as the outside, but press forming gives more uniform hardness for larger components. Of course, drop forging and press forging are defined in term of two kinds of forging methods. We could also differ forgings from its temperature, such forgings are named into cold forging, warm forging and hot forging.

3.Advantages of Press Forging

1. Higher productivity than drop forging.
2. Greater accuracy in terms of tolerances within 0.01 to 0.02 inch.
3. Dies used in press forging have less draft, therefore more complicated shapes can be forged with better dimensional accuracy.
4. The speed, pressure and travel of the die are automatically controlled, in press forging.
5. Possibility of process automation through mechanism of blank feeding and forging removal.
6. The operation is completed in a single squeezing action, saves the time.
7. The plastic deformation goes deep into the center of the work piece, provides uniform and simultaneous deformation throughout the metal.
8. The capacity of presses ranging from 500 to 9000 tons and the number of working strokes per minute can be high as 40 or even 50. Means 40 to 50 parts produced per minute.
9. The press forging, therefore, is suitable for mass production of nuts, bolts, rivets, screws, break levers, bearing races, valves, etc.

4. Limitations of Press Forging

Nevertheless, the press forging has certain limitations, these are:
1. The initial capital cost is higher compared with drop forging, because the cost of crank press is always higher than that of an equivalent hammer.
2. The difficulty of descaling the blank is another short coming of this process.
3. The process is economically suitable only when the equipment is efficiently utilized.

5. FAQ

Q: What products are made from press forging?
A: Products like car wheels, bushings, gears, automobile axles, water valves, rocket nozzles, air craft structural components and kitchen sinks are produced by a hot or cold forging press.

Q: Why is press forging preferred over hammer forging?
A: There are many advantages of press forges but the biggest is its ability to deform the workpiece. Hammer forging can only affect the surface of the workpiece whereas press forging can change the shape and interior of the workpiece at the same time. Another advantage of press forging is that it is more efficient.

Q: What is the difference between the hammer and press forging?
A: Drop Forging – With drop forging (also called hammer forging), the metal billet is inserted into the die and hammered with multiple blows. This process continues the billet is shaped into form. With press forging, the metal is shaped in a uniform way from the surface to the center.