人类可能已经将锻造作为金属制造工艺数千年了。尽管锻造方法随着时间的流逝而发生了变化，但今天的过程仍然非常受欢迎。
在过去的几个世纪中，铁匠锻造金属组件通过使用锤子撞击砧表面上的加热金属。在12世纪，一些制造商开始尝试使用水力车轮来增加锻造过程中使用的锤子的大小和功率。这项创新允许生产更大尺寸的锻造金属。
Today, modern forges have evolved into sophisticated metal fabrication plants. Most of these facilities possess an array of production equipment, tools and tooling machines, and inventories. Presses and automated hammering machinery have largely replaced grueling physical labor in powering the modern smithy.
In-demand forged metal parts serve many economic sectors during the current era. Consider just a few of the vital industries which depend upon these components: construction and building trades, heavy industry and manufacturing, aerospace and aviation, gas and energy, the automotive industry, telecommunications, maritime industries, the electronics and high tech industries, and more!
在金属锻造期间，制造商通过应用热能和机械能将金属零件改革为不同的维度。例如，此过程将使钢Billot或Ingot变成新形状。从原材料到锻造部分的路径通常涉及几个步骤：
A manufacturer usually attempts to develop the general shape of the forged part at an early stage in the forging process. By cutting pieces off an extrusion into a workable form, the manufacturer distinguishes the general size of the final part, for instance. This step frequently involves mechanically separating billets of the desired size from round, square or uniquely shaped bars.
The application of heat helps create a more malleable surface. Manufacturers may heat metal alloys undergoing forging within the designated temperature ranges specified for each alloy. For instance, forging pure copper requires less heat than forging pure nickel because copper maintains a lower melting point than nickel.
Just as a blacksmith long ago might place a hot chunk of iron onto an anvil to hammer out a horseshoe, manufacturers today position heated metal precisely in order to conduct forging. Most modern facilities automatically handle this step, ensuring that heated metal crosses along an assembly line to a specific location (the lower die) for further fabrication. Facilities lacking this level of automation would need to position the hot metal into the correct configuration in order to perform forging. For instance, a worker wearing heavily padded gloves and other protective gear might transfer small pieces of hot metal from a heated bucket onto a die serving as an anvil with the assistance of very long tongs and/or an overhead hoist.
Next, the manufacturer impacts the shape of the metal part through the application of intense force. Like an old-fashioned smithy wielding a heavy tool, the metal fabricators of today apply mechanical pressure via a moving forging die to compress and manipulate the shape of hot metal parts located on a lower forging die. The manufacturer uses a heavy press or other mechanical means to strike the upper forging die against the hot metal.
大多数现代的金属制造设施可自动化当今的锻造过程。金属零件可以通过装配线进行，在制造过程中遇到多个上层和上部锻造模具。对模具的印象会改变每个阶段金属部分的外观。
当接触发生在两个关闭的上和下部模具之间时，压力将金属从极热的坯料熔化到轮辋或“天沟”区域，在该区域中，死亡使彼此接触。当死亡闭合并挤出流离失所的材料时，该区域中的金属形成了插头。多余的经常在称为“闪光灯”的部分形成脊或一系列金属毛刺。制造商以后必须修剪这种多余的金属，以获得所需的零件形状。
一个称为“真正的封闭模具”或“无闪光”的过程消除了模具中的空腔，因此闪光不会形成；采取此步骤可能会降低大量生产运行中零件生产的成本，因为制造商无需花费资源在完成过程中从金属零件上缩小闪光灯。但是，Tred封闭的伪造可能会增加与设计模具和将热金属正确定位在装配线上的成本。
After the removal of flash, manufacturers typically conduct any further required finishing on a metal part. This process may involve first acid treating or shot blasting the part to provide a better texture for the application of a surface finish. Frequently, manufacturers will conduct machining operations on forged parts. They may subject the part to milling, turning, drilling or other physical modifications to achieve the desired form.
Manufacturers currently conduct forging using a variety of metals and metal alloys. Some of the most common operations include:
Forged aluminum products offer the advantages of strength and lightweight. Manufacturers may use forging to create parts designed to function in locations in which shocks or impacts might occur, for instance. For this reason, wheel spindles, gears, and engine pistons often depend upon forged components.
Copper and its alloys provide excellent raw materials for the forging process. These materials typically undergo commercial forging without requiring any re-strikes. The malleability of copper may allow the use of a single die press and permit a rate of 200 to 600 forged pieces completed per hour in automated environments.
镁也很容易锻造。金属在锻造后耐受广泛的加工。
Nonmagnetic stainless steel usually requires a higher forging temperature than magnetic stainless steel. Modern manufacturers perform a wide array of forgings using stainless steel, since these alloys play an important part in numerous industries.
The strength of forged steel contributes to the popularity of this product. Numerous steel industrial parts undergo open die forging, for example.
Some important differences exist between the process of casting and forging. These difference contribute to structural differences in a metal part:
During casting, a manufacturer typically heats metal into a liquid form and then pours the molten material into a mold to cool. As it hardens, the metal will recrystallize in a new shape. Bubbles of gases may become trapped within the cooling liquid and small surface irregularities may occur where gases escaped. By contrast, during forging, the manufacturer applies thermal energy and pressure to alter the shape of an existing metal part. The forging process typically compresses and compacts the metal and causes grain flow changes in conformity with the shape of the part.
Depending upon the manufacturing environment, the forging process today generally produce stronger, more reliable and more impact-resistant metal parts than the casting process. Forged parts may display superior tensile strength, fatigue strength and yield strength. A forged part typically must endure greater deformation before failing than a cast part.
Forging helps reduce problems caused by porosity, which may occur during the casting process as bubbles of gas become trapped inside the molten metal. By compressing hot metal, forging permits the removal of these defects (which sometimes weaken cast metal parts). Thus, well-forged parts usually demonstrate better strength and impact resistance. Depending on the manufacturing environment and the degree of automation, forging often proves more cost-effective and permits closer tolerances than casting. This process represents a flexible, popular alternative for metal fabrication.
The process of metal forging offers a number of advantages for manufacturers. Whether you seek forged metals in high volumes or smaller quantities, you’ll obtain a number of benefits.
Compared with castings, extrusions or machined bar stock, forging sometimes furnishes a cost-effective alternative. This process reduces the time required to generate a metal part.
Additionally, forging typically provides an opportunity for the manufacturer to improve the strength of the metal component. Whether forging stainless steel or relying upon aluminum forgings, a manufacturer by using this process may enhance leak resistance in some items. It may help strengthen thin metal surfaces in some products, reducing leaking potential.
Ultimately, forging enables some manufacturers to supply metal parts engineered within close tolerances. Companies maintaining rigorous quality controls standards attest to the benefits of this process. A grain flow comparison of the interior of the metal before and after forging may prove illuminating also!
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From a contract manufacturing firm, BuntyLLC evolved into a full service custom machined, forged and cast metal parts fabrication enterprise. We supply global solutions from our headquarters in Greenville, South Carolina.
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