6. Metal Forging

This chapter first presents a brief history and industrial importance of metal forging (including the author’s real-life contribution to the industry) and then highlights the advantages and limitations of forging process. Different types of forging operations (e.g., open-die forging, closed-die forging, flash-less forging) are classified and described with the aid of sketches. Hammer forging and press forging are also differentiated and explained. Engineering analysis of open-die forging is presented taking into consideration the forging shape factor and forging force for upset forging/cold-heading. The role of friction in sticky and sliding regions in open-die forging is also analyzed by presenting appropriate mathematical models. This chapter contains 10 diagrams, 16 worked numerical examples, 10 formulae, 8 problems, and 9 MCQs with their answers provided at the end of the book.