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Forging

Forging

Forging2025-03-26T23:14:07+00:00
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Novelty Structures is a supplier of Steel Forging and Machining services of Turkish Forging Industry.

Various forged steel parts

What is Forging?

Forging is a widely used manufacturing process that involves shaping metal through compressive forces, typically delivered via a hammer or press. Forged parts are renowned for their strength, durability, and reliability, making them critical components in industries such as automotive, aerospace, energy, construction, and more.

  • High Strength and Durability: Forging aligns the metal’s grain structure, enhancing mechanical properties like tensile and impact strength. This makes forged parts particularly suited for load-bearing and high-stress applications.

  • Improved Toughness: Forged components exhibit superior toughness and resistance to fatigue due to the elimination of voids, inclusions, and defects that may arise in casting or machining processes.

  • Dimensional Accuracy: Modern forging methods can achieve tight tolerances, reducing the need for extensive post-machining.

  • Material Variety: Forging can be performed with various metals, including carbon steel, stainless steel, aluminum, titanium, and nickel alloys, allowing flexibility based on application requirements.

Carbon Steels

  • Commonly used for automotive and industrial parts, offering a balance of strength and cost.

Stainless Steels

  • Provide excellent corrosion resistance for applications like marine and food processing.

Alloy Steels

  • High-performance parts requiring wear resistance and toughness, such as gears and shafts.

Aluminum Alloys

  • Lightweight and corrosion-resistant, used in aerospace and automotive.
Forged Flange

Forging Applications

Automotive

Crankshafts, connecting rods, gears, axles, wheel hubs, tie rods, suspension arms

Heavy Machinery

Hydraulic cylinders, pistons, track links, rollers, gears, drive shafts

Energy

Steam turbine rotors, wind turbine shafts, gear hubs, pressure vessel components

Railroad

Railcar couplers, wheel axles, bearings, suspension brackets, springs

Agricultural

Plowshares, tiller blades, tractor axles, chains, hooks, gears

Marine

Propeller shafts, rudders, anchors, flanges, and marine fittings

Oil and Gas

Drill bits, drill collars, flanges, valves, connectors, couplings

Medical

Orthopedic implants (e.g., hip/knee joints), surgical instruments (scalpels, forceps, clamps)

Forged Parts
Various forged steel components
Steel forging components

Pre-Forging Operations

Cutting to Length

  • Cutting the raw material (billet, bar, or ingot) to the required size and weight.

  • Reduces waste and ensures consistent material input into the forging process.

Heating

  • Heating the material to the forging temperature (hot forging: ~1000°C for steel, warm forging: ~700–900°C).
  • Reduces material strength, increases ductility, and makes it easier to deform.

Surface Cleaning

  • Removing rust, scale, dirt, or other contaminants using methods like pickling, abrasive cleaning, or shot blasting.
  • Prevents defects during forging and ensures a clean surface for better material flow.

Lubrication

  • Applying lubricants (e.g., graphite-based or oil-based) to the tools and workpiece.
  • Reduces friction, prevents sticking, and extends tool life.

Pre-Forming

  • Rough shaping or pre-forging the material into an intermediate shape (using rollers or presses) before final forging.
  • Reduces the amount of material flow needed in the main forging operation,

Forging Operations

Open-Die Forging

Description:

  • The workpiece is compressed between flat or contoured dies without completely enclosing it.

Purpose:

  • Used for large, simple shapes like shafts and cylinders; ensures directional grain flow for improved strength.

open forging

Closed-Die Forging

Description:

  • The material is compressed within a die cavity to take the exact shape of the cavity.

Purpose:

  • Produces complex, precise shapes with minimal waste. Ideal for mass production of high-strength components.
Closed Die Forging

Drop Forging

Description:

  • Drop Forging requires a hammer to deliver high-energy blows to shape the workpiece in a die.

Purpose:

  • Increases the speed of the forging process and ensures high accuracy in die replication.

drop forging

Press Forging

Description:

  • The workpiece is shaped through continuous pressure applied by a press (hydraulic or mechanical).

Purpose:

  • Allows better control over material flow and is suitable for high-strength and large components.

press forging

Post-Forging Operations

Trimming

  • Cutting off excess material (flash) formed during closed-die forging, usually using a trimming press.
  • Ensures the forged part meets dimensional accuracy and eliminates unnecessary material.

Heat Treatment

  • Processes like annealing, normalizing, quenching, and tempering to refine grain structure and improve mechanical properties.

  • Enhances strength, hardness, ductility, or toughness based on application requirements.

Non-Destructive Testing (NDT)

  • Inspecting the forged part using ultrasonic testing, X-rays, magnetic particle testing, etc., to detect internal and external defects.
  • Ensures the part meets safety and quality standards without compromising its integrity.

Surface Finishing

  • Operations like grinding, polishing, or machining to meet precise dimensional and surface quality requirements.
  • Ensures a smooth surface, dimensional accuracy, and aesthetic quality.

Inspection

  • Final inspection for dimensional accuracy, mechanical properties, and surface defects.
  • Guarantees compliance with specifications and customer requirements.
steel forging component2

Forging Costs and Pricing

Material Costs

  • Raw Material Selection: High-grade materials like steel, titanium, or aluminum are more expensive but may be necessary.

  • Material Utilization: Wastage from trimming or flash increases costs.

forging work pricing

Tooling & Mold Costs

  • Die Design and Manufacturing: Custom dies for complex shapes are expensive to create.

  • Tool Life: Shorter die life increases tooling expenses.

  • Maintenance: Regular die upkeep prevents failures but adds to costs.

Energy Costs

  • Heating Requirements: Energy needed for heating materials.

  • Process Type: Different forging methods (hot, warm, cold) require varying energy levels.

  • Press Operation: Energy used by forging equipment like presses or hammers.

Processing Time

  • Cycle Time: Longer forging cycles increase production costs.

  • Pre- and Post-Processing: Additional activities like surface preparation, machining, or heat treatment increase costs.

Production Volume

  • Economies of Scale: High production volumes reduce per-unit costs.

  • Batch Size: Smaller batches lead to higher costs due to setup inefficiencies.

Equipment Costs

  • Machine Investment: Significant capital is required for forging machines like presses or hammers.

  • Maintenance and Depreciation: Long-term wear and tear increase costs.

Quality and Scrap

  • Defects and Rework: Costs rise with defects or the need to rework parts.

  • Quality Control: Inspections and testing add to overall expenses.

Labor Costs

  • Skilled Workforce: Skilled operators command higher wages.

  • Automation: Initial investments in automation reduce labor costs over time.

FAQ

Can you produce custom designs ?2025-03-26T23:00:32+00:00

Yes, we offer custom forging services based on your specifications, including CAD designs or blueprints. Our team works closely with you to ensure your design requirements are met.

What size or weight range can you handle?2025-03-26T22:53:03+00:00

Our capabilities vary depending on the forging method. We can handle small, intricate components weighing just a few hundred grams to larger pieces weighing several kgs. Contact us for specific size and weight limits.

What kind of tolerances can you achieve?2025-03-26T22:53:28+00:00

We maintain tight tolerances, but specific tolerances depend on the material, design, and forging method. Please share your project details for precise information.

Do you offer complementary services like machining or heat treatment?2025-03-26T22:54:03+00:00

Absolutely. In addition to forging, we offer a range of secondary services, including heat treatment, machining, surface finishing, and inspection.

How do you ensure quality?2025-03-26T22:54:43+00:00

Quality is at the core of our operations. Our quality assurance measures include:

  • Certified Processes: Adherence to ISO 9001.
  • Material Traceability: Full documentation of material origins and properties.
  • Non-Destructive Testing (NDT): Techniques like ultrasonic testing, magnetic particle inspection, and dye penetrant testing to detect internal and surface flaws.
  • Dimensional Inspections: Using CMM (Coordinate Measuring Machines) for precision measurements.
  • Mechanical Testing: Tensile, hardness, and fatigue testing to confirm performance.
Can you provide material certifications?2025-03-26T22:55:11+00:00

Yes, we provide full traceability and material certifications upon request.

How are forged parts packaged?2025-03-26T22:55:59+00:00

We ensure safe packaging to protect forged parts during transit. This includes:

  • Wooden crates or pallets for heavy parts.
  • Protective coatings or wraps for corrosion resistance.

We ship domestically and internationally, with delivery times varying by destination.

forging fasteners

What is Novelty Structures offering?

Novelty Structures supplies custom forging parts for various applications in different industries.

Get into contact with our team to further discuss your needs.

Novelty Steel offers Turkish steel fabrication solutions to various industries with broad scope of applications.

For all inquiries please contact : info@noveltystructures.com

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