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Reasons To Use Stainless Steel Precision Turned Components

 

There are several reasons why stainless steel precision turned components are used in various industries and applications, some of which include:

  • Hygienic: Stainless steel is easy to clean and does not harbor bacteria or other microorganisms, making it ideal for use in food and medical applications where hygiene is critical.

  • Non-toxic: Stainless steel is non-toxic and does not leach harmful substances, making it safe for use in applications where toxicity is a concern.

  • Aesthetic appeal: Stainless steel has a modern and stylish appearance that is often used to add a touch of elegance to products and applications.


  • Recyclability: Stainless steel is a highly recyclable material, making it environmentally friendly and an excellent choice for use in applications where sustainability is important.
  • EXCEL FORGING is a reputed manufacturer, supplier and exporter among the few ISO 9001:2015 registered CNC precision auto parts in India. We manufacture custom parts and spares for various companies as per their requirement. Having mare than 3 decades of experience, we ensure the best quality metals, materials and return on any flawed supplies or orders.

    Contact Excel Forging for any type of precision turned components inquiry from INDIA.

    Forged steel is an alloyed metal which has been heated and then cooled rapidly. It’s used for making tools, machinery and equipment. We explain forged steel and look at the power forge technique and various types of forged steel. Additionally, we discuss some of the benefits of using forged steel in your projects.

    What Is Forged Steel?

    Steel is a metal that can be shaped into any number of useful forms. However, it cannot be easily melted like aluminum or cast like iron. Instead, steel must be heated to very high temperatures before being formed by hammering, drawing, rolling, punching, etc. This process is called forging.

    The most common type of steel is carbon steel, but there are many other types available. The main difference between them is their composition. Carbon steels contain varying amounts of carbon (C), manganese (Mn), phosphorus (P), sulfur (S), silicon (Si), chromium (Cr), nickel (Ni) and molybdenum (Mo).

    What is Forging?

    Forging is a metal shaping technique using localized force, usually applied by striking against another piece of metal. In some cases, it involves heating one piece of metal below its melting point while pressing the heated metal into another piece of metal. Forging is often associated with heat treatment processes such as quenching, tempering, hardening and annealing.

    The earliest known examples of forging date back to the Bronze Age, circa 3200 BC, where bronze objects were produced by smelting copper ore and adding tin. These early metalsmiths forged many different types of items including weapons, jewelry, tools and household goods.

    Since its origins in the fertile Crescent, forging has experienced significant change, resulting in a more effective, faster and more robust process. Today, forging is most commonly done with the use of forging press or hammering tools that power by electricity, hydraulics or compressed air.

    Some of the common material used for forging include carbon steel, alloy steel, micro alloy steel, stainless steels, aluminum and titanium.

    What is the purpose of forging?

    The purpose of forging is to make metal into something else entirely. Forging is a highly specialized type of manufacturing that creates metal parts, usually stronger than those produced by casting. Casting is another common method of producing metals that involves heating molten metal and pouring it into molds. While both processes produce similar finished products, there are many differences in how each one works.

    Forged parts are typically much stronger than castings because they contain fewer imperfections. The hot forging process seals small flaws in the metal, including tiny cracks and air pockets. These defects aren’t present in castings.

    Metal forging also breaks down impurities in the metal. Impurities like sulfur and carbon are distributed evenly throughout the metal during casting. However, forging heats the metal and presses it together, breaking down these compounds and distributing them throughout the metalwork. This greatly reduces the amount of impurities found in forged parts.

    Finally, forging distributes certain elements within the metal. When molten metal is poured into a mold, the liquid metal cools and solidifies almost immediately. Because the metal doesn’t have enough time to fully cool, impurities remain trapped in the metal. By contrast, the hot forging process allows the metal to slowly cool, allowing impurities to disperse throughout the metal.

    What are the different types of forging?

    Hot forging is used to make parts out of steel, aluminum, titanium, nickel, copper, magnesium and zinc. Cold forging is used to make forged parts out of cast iron, stainless steel, carbon steels, tool steels and special steels. Hot forging uses heat to melt the material into shape. Cold forging uses pressure to mold it into shape.

    Hot Forging

    Hot forging is used to make parts out of steel that are too hard or brittle to be formed by cold working alone. The process involves heating the material to over 2,300 degrees Fahrenheit and then hammering it into shape. This creates a stronger part than you could ever get from cold forming alone.

    The process starts with a bar of steel that needs to be heated to around 1,500 degrees Fahrenheit. Then, the bar gets hammered into shape. After the forging is complete, the piece cools down quickly and becomes much harder than it would have been otherwise.

    Need a hot forging manufacturing company? Contact us today!

    Cold Forging

    Cold forging typically refers to forging metal at room temperature, although any temperature below recrystallization is possible. Cold forging often involves forming parts with complex shapes and tight tolerances. This process is used primarily for making tooling dies, where the finished part must fit perfectly into the die cavity. Cold forging is also used to make small quantities of components that require close tolerances and precise dimensions.

    Despite this hindrance, cold forged products tend to have better dimensional control, surface finish and product uniformity than those produced by hot forging. Cold forging produces parts that are stronger and lighter than hot forged counterparts, while maintaining similar mechanical properties.

    However, cold forging requires more powerful machinery and may call for the usage of intermediate annealing processes. In addition, cold forging is less versatile than hot forging, since it cannot produce many types of forgings.

    Need a cold forging company? Contact us today!

    What are the different forging processes?

    The process of metalworking is often referred to as “forging.” But what does that really mean? There are a lot of terms used to describe certain types of metalworking processes, such as drawing, upsetting, compression, etc., but the most common term you’ll hear is forging. In general, it refers to the creation of metal parts by deforming a blank piece of material. Depending on how much deformation occurs during the forging process, the resulting part might be called a forged item, a drawn item, a formed item, a stamped item, etc.

    Beyond basic hot and cold forging there are numerous specific processes. These include:

    Drawing – Decreases the width of the product and increases length

    Upsetting – Increases the width of the product

    Compression – Provides forging flow in multiple or custom direction

    Forming – Forges in one direction

    Stamping – Forms metal into a desired shape

    Drop Forging Process

    The drop forging process uses a special type of steel called high carbon tool steels. These materials are harder than standard low carbon tool steels used in traditional manufacturing processes. This allows the material to take a greater amount of heat during the forging process without cracking.

    In addition to being stronger, high carbon tool steels are machinable. They require more cutting energy and less wear on the tools. As such, they are often preferred over low carbon tool steels because they make the operation faster and cheaper.

    High carbon tool steels are commonly found in automotive applications where the strength of the final product is important. However, they are also common in aerospace, medical device and jewelry industries.

    Open Die Forging Process

    The open die forging process, sometimes called Smith Forging, is used to make complex shapes such as forgings, billets and bars. This method is often used for making small parts because it does not require expensive tooling. In addition, it is possible to use the same dies and tools to produce many different types of products.

    Closed Die Forging Process

    The closed die forging process uses molds that are attached to an aniline block. A hammer forces molten metal to fill the mold cavities. Metal flows out of the dies during each strike of the hammer. This process is commonly known as “closed die forging.”

    A typical closed die forging operation consists of several steps. First, the die must be prepared. Next, the die is placed inside a blank holder. The blank holder holds the die securely while it is being forged. After the component is formed, the component is removed and the finished product is ready for further processing.

    This method allows for the creation of complex shapes, such as those found in car engines. However, closed die forging requires high initial tooling costs because multiple molds must be built and assembled together. As a result, closed die forging is typically limited to long run manufacturing processes.

    Press Forging Process

    The press forging process involves the use of multiple dies to form the component of material into a single piece. This type of manufacturing allows manufacturers to produce large quantities of parts quickly and cheaply.

    In most cases, the part is formed by placing it directly onto the bottom die and applying pressure. As the part is compressed, heat is generated, resulting in a change in the physical properties of the metal. Depending on the amount of force applied, the part has been pressed. When the required shape is achieved, the part is removed from the lower die.

    A second set of dies called a compression die is used to apply the necessary pressure. The part is placed on the lower die and the upper die moves downward, compressing the part. As the part continues to compress, it start forming in to the cavity of dies. Once the part reaches the specified shape, the process is complete and the part is ejected from the lower die.

    Roll Forging Process

    Metal shaping processes like extrusion and pressing are well known in the manufacturing world. But roll forging is gaining popularity because of its ability to form many shapes without the use of dies. This allows manufacturers to save money, space, energy and material costs. In addition to being cost effective, roll forging offers many advantages over traditional metal forming methods.

    The most notable advantage is the lack of flash, which occurs when the edges of the metal do not meet up perfectly during the forging process. Flash can cause problems such as surface defects, warping and poor quality. With roll forging, there is no need to worry about flash since the entire piece of metal is rolled into the final shape.

    Another benefit of roll forging is the formation of a fine grain structure. When compared to conventional metal processing techniques, roll forging produces parts with a finer grain structure. This makes the finished product stronger and less prone to breakage. Finally, roll forging does not require expensive tooling, which reduces overall production costs. Ring are mostly manufactured using ring rolling machine. Cross-wedge rolling (CWR) is the latest and economical technology to produce preform with variation in cross section diameters. In this process the workpiece rolls between the dies to create various diameters across the length of the workpiece.

    Upset Forging Process

    The upsets forge process is a method of making steel forgings that involves upsetting the material to increase the diameter of the part. This process is often used to make large forged parts such as axle shaft, round head shaft, bolts and pins.

    Upsets forge is a type of continuous forging process where the workpiece is continuously fed into the press and the dies are closed around the workpiece while the die opening is gradually increased in size. When the die opening reaches its maximum size, the dies close completely and the material is compressed to form the desired shape. After forming, the dies open and the workpiece is removed.

    This method allows for greater productivity and lower costs compared to traditional methods. Steel forgings are typically produced on a vertical press; however, some companies use horizontal presses.

    Isothermal Forging Process

    Isothermal forging is a closed-die process in which the dies and the workpieces are heated to the same temperature, so that forming can take place without loss of temperature in the workpiece.  In this process, the workpiece is formed to shape at a slow rate and at a temperature almost equal to that of the heated die. It’s a preferred process for forming engineered parts, including jet-engine and other aerospace components in high-density lightweight alloys. 

    What kind of equipment is used for forging?

    The most popular type of forging is the hammer and forging press, which uses the same basic concept as the original method. The difference lies in the way the hammer is moved. In a traditional forge, the hammer is held stationary while the anvil moves down towards it. This process is called “drop forging.” However, drop forging requires a lot of force and is difficult to control. A better alternative is the use of a hydraulic press, where the entire machine is lowered onto the material.

    Summary

    Forging is a process used to produce metals into desired shapes. There are many types of forging processes, including hammering, extrusion, rolling, stamping, etc. Each type of forging involves heating metal to a very high temperature, then applying pressure to form it into the desired shape. In some cases, the heated metal is forced through a die to create the final product.

    The term “forging” can refer to either the entire process or just one step of the process. Some manufacturers use a combination of several different forging techniques to achieve the end result.

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