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A forging machine used is a device that changes metal shape through compressive stresses. It is an integral part of the machinery industry. There are two main types of machines, the impact type and the pressure type.
Impact-type forging machines
Impact-type forging machines apply force to the workpiece in a single blow and are further divided into drop forges and hammer forges.
The first is a drop forging machine that takes a drop hammer. The hammer is moved by means of a power source driven through a vertical distance. Then, the weight of the hammer is dropped onto the workpiece. It is usually used for light metallic parts.
Hammers are another typical impact-type forging machine. They come in various sizes and forms. Power sources include steam, air, water, or electricity. Power hammers forge metals by striking them with a moveable hammer. They are flexible tools that can be used for artistic blacksmithing in addition to shaping metal for mechanical purposes.
Pressure-type forging machines
These machines shape metals by applying high-pressure oil. They include a hydraulic press forging machine and a screw press forging machine.
A hydraulic press forging machine uses an electric motor and hydraulic pump to apply pressure to metal parts. It is said to be more energy-efficient than drop hammers. The machine can be used for heavy load capacity and high tonnage requirement.
A screw press forging machine makes use of the electric motor that turns the clutch to apply pressure. It is said to need little maintenance and has long operational lifespans. Yet, it is not as efficient as hydraulics in terms of tonnage and energy use.
Hammer Size:
The forging hammer size is typically represented in units like tonnage. It denotes the weight of the hammer and directly influences the energy it imparts on the workpiece during forging. For example, a hammer with a tonnage rating may be suitable for heavy industries.
Die Material:
In most cases, the forging dies are made of steel due to its strength and durability. Nevertheless, die construction may also incorporate other materials per the requirements, like titanium or certain alloys, to achieve specific characteristics or tolerances for particular industries or applications.
Hammer Types:
There are two types of hammer machines: the power hammers and the steam hammers; both are employed to shape metal by dropping a heavy ram onto the metal, which is then heated and placed on a die. These types of forging hammers have both similarities and differences that affect the forging process.
Punch Size:
The size of the forging hammer punches can vary based on the specific forging operation, press size, and equipment used. Punches are typically made from high-strength steel and are designed to withstand the forces and impacts involved in forging.
Regular lubrication:
Regular lubrication is crucial forging machine maintenance to ensure efficient operation and prevent machine wear and tear. It helps reduce friction between moving parts, thus facilitating smooth operation. Proper lubrication also aids in mitigating the effects of machine parts rubbing against each other, thereby extending the lifespan of the forging machines.
Check and tighten bolts and nuts:
It is critical to inspect and tighten the forging machine bolts and nuts periodically to ensure that all fastener components are in a good state of use and firmly fastened. This helps improve machine stability, thus ensuring safety during operation. Regular inspection and tightening can effectively avoid problems like looseness and falling, which may impact production efficiency and quality.
Replace wearing parts:
Typically, the forging machines are manufactured using strong and durable materials to withstand high-temperature conditions. Over time, however, these machines may wear or damage and need to be replaced to prevent these issues from arising, thus ensuring continuous stable and efficient operations, improving production efficiency and quality. Timely replacement of wearing parts can also prevent equipment from being damaged beyond repair.
Aerospace industry
A critical application area for forging presses is the aerospace industry, where they are used to produce highly intricate yet lightweight structural components for aircraft, rockets, and satellites. The strength-to-weight ratio of aerospace components is crucial, and machines are capable of producing parts with high strength, which is very important when forging components for the aerospace industry.
Medical fields
For example, forging creates prosthetic human body parts like hip joints, knees, and bones. In addition, it also helps to create therapeutic equipment like wheelchairs, braces, walkers, and crutches that have to be lightweight yet durable. The material benefits of forgings make them ideal choices for surgical instruments, implants, and prosthetics, among other devices.
Automotive industry
The automotive industry largely uses the rotary and impact forging machines. Examples of these machines are pneumatic hammers, power hammers, and hydraulic presses. Pneumatic hammers strike the hot metal repeatedly to shape the desired part. Automotive components such as crankshafts, axles, transmission parts, and gear blanks are often made by these techniques.
Cylinder block manufacturing
Forging machines are extensively used in manufacturing automobile cylinder blocks. The forging process is chosen due to its cost-effectiveness when producing large quantities and its ability to create dense, strong materials.
Oil and gas industry
In the oil and gas industry, hydraulic presses are primarily used for forging components like valves, flanges, and fittings, among other things. These presses shape metals into complex parts used in pipelines and refineries.
Heavy machinery sectors
Yaw shafts, brake discs, gears, and transmission shafts are all examples of heavy machinery sectors. Also known as the backbone of industrial engineering, the sectors refer to mechanically engineered machines and parts that are largely used in factories, manufacturing plants, etc.
Going through the details before buying a used forging press for sale will ensure a wiser purchase that will serve the business better. Some of the things to look for when buying a secondhand forging machine are:
Overall condition
It is important to look at the overall condition of the used forging press. Check for any signs of damage, corrosion, or abnormal wear. Look at the die, slide, ram, and forging press bed to see if there are any defects. Inspecting the overall condition of the used forging machine helps to know its ability to deliver effective services to the business.
Maintenance history
A used forging machine's maintenance history reveals essential details about its servicing. Machines with regular maintenance will function better than those that have hardly been maintained. Also, find out if there has been any major repair and the forging machines' working hours.
Power requirements
The power requirement of a used forging press machine can greatly impact the capacity to produce forged items. An electrohydraulic forging machine will have different power needs than a mechanically driven one. Choose a machine with power needs that will suitably fulfill the production goals.
Available die sets
If opting for a used die forging machine, check what die sets come with it. Some machines may arrive with only one or two sets that limit production capabilities. Investing in extra die sets will raise production costs. Look for a machine that comes with enough die sets to meet the manufacturing needs.
Q1: What materials are suitable for forging?
A1: Almost all metals and alloys are suitable for forging, including carbon steel, stainless steel, alloy steel, aluminum, brass, copper, and titanium. However, specific metal compositional structures must be considered to ensure that they can be deformed when heated.
Q2: Is machining necessary after forging?
A2: Yes, sometimes after forging, machines are used to ensure that the parts are made to accurate measurements. This is especially important for forging parts that require a precise fit or assembly with other components.
Q3: Are one-off custom forgings cheaper than die forging?
A3: Yes, for custom forging machines, the cost is usually less because there is no need to build an expensive die. On the other hand, if one is forging many pieces, then die forging will be cheaper in the long run.
Q4: What is the difference between forging and casting?
A4: Forging machines change the shape of materials by pressing or hammering them, whereas casting involves pouring molten material into a mold and letting it cool and solidify.
