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Why Use Drop Forging?

Forging, casting, machining and welding fabrication are the four main metal forming technologies. So why use drop forging? Here we discuss this issue in detail in side of design, economy, environment, quality, material, application, etc. So that you could have a deeper understanding of drop forging.
why use drop forging
Drop forged components make possible designs that accommodate the highest loads and stresses. Recent advances in drop forging technology have greatly increased the range of properties available in steel forgings. To the designer, the structural integrity of forgings means safety factors based on material that will respond predictably to its environment without costly special processing to correct for internal defects.

Economically, drop forged products are attractive because of their inherent superior reliability, improved tolerance capabilities, and the higher efficiency with which forgings can be machined and further processed by automated methods. Steel Forgings are produced economically in an extremely broad range of sizes. With the increased use of special punching, piercing, shearing ,trimming, and coining operations, there have been substantial increases in the range of economical drop forging shapes and the feasibility of improved precision. However, parts with small holes, internal passages, re-entrant pockets, and severe draft limitations usually require more elaborate forging dies and more complex processing, and are therefore usually more economical in larger sizes.

Ecologically, drop forgings are attractive because they are recyclable.

The degree of structural reliability achieved in a drop forging is unexcelled by any other metalworking process. There are no internal gas pockets or voids that could cause unexpected failure under stress or impact. Often, the drop forging process assists in improving chemical segregation of the forging stock by moving centerline material to various locations throughout the forging. To the production employee, the structural reliability of drop forgings means reduced inspection requirements, uniform response to heat treatment, and consistent machinability, all contributing to faster production rates and lower costs. Designers and materials engineers are recognizing the increasing importance of resistance to impact and fatigue as a portion of total component reliability. With the use of proper materials and heat treatments, if required, improved impact strength of drop forged components is achievable. The resulting higher strength-to-weight ratio can be used to reduce section thickness in part designs without jeopardizing performance characteristics of safety. Weight reduction, even in parts produced from less expensive materials, can amount to a considerable cost savings over the life of a product run.

The consistency of material from one forging to the next, and between separate quantities of drop forgings is extremely high. Forged parts are made through a controlled sequence of production steps rather than random flow of material into the desired shape. Uniformity of composition and structure piece-to-piece, lot-to-lot, assure reproducible response to heat treatment, minimum variation in machinability, and consistent property levels of finished parts. Dimensional characteristics are remarkably stable. Successive drop closed die forgings are produced from the same die impression,and because die impressions exert control over all contours of the forged part, the possibility of transfer distortion is eliminated.

For cryogenic applications, drop forgings have the necessary toughness, high strength-to-weight ratios, and freedom from ductile-brittle transition problems. So it is widely used in industrial applications.

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