Roll Forging

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1. Roll Forging

Roll forging is a process where round or flat bar stock is reduced in thickness and increased in length. Roll forging is performed using two cylindrical or semi-cylindrical rolls, each containing one or more shaped grooves. A heated bar is inserted into the rolls and when it hits a stop the rolls rotate and the bar is progressively shaped as it is rolled through the machine. The piece is then transferred to the next set of grooves or turned around and reinserted into the same grooves. This continues until the desired shape and size is achieved. The advantage of this process is there is no flash and it imparts a favorable grain structure into the workpiece. Examples of products produced using this method include axles, tapered levers and leaf springs.

http://www.kt-forge.co.uk/roll-forging

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18. Forging

Virtually all metals that can be moulded / drawn out may be forged by first heating and then hammering it in to the desired shape. A billet, wrought bar, cast or sintered ingot etc.. may be forged. Forging improves the toughness and strength of improving orientation of the metal grain structure. The repeated heating and hammering causes the metal to become more dense and the grain "flow lines" to follow the contour of the end product.

http://forging.ktforge.co.uk

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31. Swaging

T=Swaging is a forging process in which the dimensions of an item are altered using a die or dies, into which the item is forced. Swaging is usually a cold working process; however, it is sometimes done as a hot working process. Virtually all metals that can be moulded / drawn out may be forged by first heating and then hammering it in to the desired shape. A billet, wrought bar, cast or sintered ingot etc.. may be forged. Forging improves the toughness and strength of improving orientation of the metal grain structure. The repeated heating and hammering causes the metal to become more dense and the grain "flow lines" to follow the contour of the end product.

http://www.ktforge.co.uk/swaging

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43. Hammer Forging

The most common type of forging equipment is the hammer and anvil. Principles behind the hammer and anvil are still used today in drop-hammer equipment. The principle behind the machine is simple: raise the hammer and drop it or propel it into the workpiece, which rests on the anvil. The main variations between drop-hammers are in the way the hammer is powered; the most common being air and steam hammers. Drop-hammers usually operate in a vertical position. The main reason for this is excess energy (energy that isn't used to deform the workpiece) that isn't released as heat or sound needs to be transmitted to the foundation. Moreover, a large machine base is needed to absorb the impacts. To overcome some shortcomings of the drop-hammer, the counterblow machine or impactor is used. In a counterblow machine both the hammer and anvil move and the workpiece is held between them. Here excess energy becomes recoil. This allows the machine to work horizontally and have a smaller base. Other advantages include less noise, heat and vibration. It also produces a distinctly different flow pattern. Both of these machines can be used for open-die or closed-die forging. A forging press, often just called a press, is used for press forging.

http://hammer-forging.ktforge.co.uk

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A self-lubricating bearing, often referred to as a "self-lube bearing," is a type of bearing designed to operate without the need for external lubrication, such as grease or oil. These bearings are used in various applications where traditional lubrication methods may be impractical or where maintenance requirements need to be minimized. Self-lubricating bearings typically incorporate a solid lubricant within the bearing material or have special reservoirs or channels designed to release lubrication as needed during operation. The primary advantage of self-lubricating bearings is their ability to reduce friction and wear over time without the need for manual lubrication or maintenance.

https://www.bearingswebshop.com/product-category/self-lube-bearings/

48. Drop Forging

Drop forging is a metal shaping process, the metal to be formed is first heated then shaped by forcing it into the contours of a die, this force can be in excess of 2000 tons. The drop forging process can be performed with the material at various temperatures. Hot Forging: During hot forging the metals are heated to above their recrystallization temperature. The main benefit of this hot forging is that work hardening is prevented due to the recrystallization of the metal as it begins to cool. Cold Forging: Cold Forging is generally performed with metal at room temperature below the the recrystallization temperature. Cold forging typically work hardens the metal. There are two types of drop forging, open die and closed die. Open die drop forging requires the operator to position the work piece while it is impacted by the ram. The die attached to the ram is usually flat or of a simple contour, most of the shaping is achieved by the operator physically positioning the work piece before each stroke of the ram. There are also special dies which can be used to cut the metal, form holes or notches.

http://www.ktforge.co.uk/drop-forging

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53. Cold Forming

Cold forging is a high speed manufacturing process whereby metal is shaped at room temperature often without the need for the removal of material. A simple blank is placed within a die and a punch is pressed into the blank. The blank then takes on the form of the punch and the die. By utilising multiple dies and punches in succession very complex shapes can be achieved. Metal is forced beyond its yield (elastic) limit and retains its altered shape upon removal from the die. The metal is not forced beyond its tensile strength, otherwise fracturing would occur (the exception is when trimming or piercing). Historically cold forming has been an experienced based technology, but this is changing as new computer based analytical tools are constantly being developed.

http://www.ktforge.co.uk/cold-forming

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56. Hammer Forging

http://www.kt-forge.co.uk/hammer-forging

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58. Smith Forging

Forging worked between flat or simple contour dies by repeated strokes and manipulation of the workpiece. Also known as "hand" or "flat die " forging.Heavy workpieces could be processed using a smith-forging hammer, and smaller forgings are die formed in drop hammers. Smith forging hammers are typically steam or air-operated, consisting of a power actuated ram supported by a heavy cast iron frame. The final product is a result of the ram being powered into the dies containing the workpiece.

http://smith-forging.kt-forge.co.uk

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60. Hot Forging

Hot forging is the plastic deformation of metal at a temperature and strain rate such that recrystallization occurs simultaneously with deformation, thus avoiding strain hardening. For this to occur, high workpiece temperature (matching the metal's recrystallization temperature) must be attained throughout the process. A form of hot forging is isothermal forging, where materials and dies are heated to the same temperature. In nearly all cases, isothermal forging is conducted on superalloys in a vacuum or highly controlled atmosphere to prevent oxidation.

http://hot-forging.ktforge.co.uk

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