High precision forged metal parts 4140 Alloy Steel Gear Forging ISO
Product Description and Process
Hot Forging Drop Forging Process 4140 Alloy Steel Gear Products
Production process: metal hot forging process
Machining process: CNC machine, machining center, lathe, mill
machine, drill machine, etc.
Surface treatment process: paint coating, electrophoretic coating,
electrogalvanizing coating, black oxide coating, powder coating,
Product Material and Uses
Normally produce with low carbon steel, medium carbon steel, low
alloy steel, such as 1020 steel, 1035 steel, 1045 steel, 16Mn,
Q235, Q345, A105, 20MnMo, 35Crmo, 42CrMo, etc.
The steel forging products are widely used for auto-car parts,
truck parts, train parts, vehicle components, construction
machinery components, other machinery components, etc.
Forging Advantages and disadvantages
Forging can produce a piece that is stronger than an equivalent
cast or machined part. As the metal is shaped during the forging
process, its internal grain texture deforms to follow the general
shape of the part. As a result, the texture variation is continuous
throughout the part, giving rise to a piece with improved strength
characteristics. Additionally, forgings can target a lower total
cost when compared to a casting or fabrication. Considering all the
costs that are involved in a product’s lifecycle from procurement
to lead time to rework, and factoring in the costs of scrap,
downtime and further quality issues, the long-term benefits of
forgings can outweigh the short-term cost-savings that castings or
fabrications might offer.
Some metals may be forged cold, but iron and steel are almost
always hot forged. Hot forging prevents the work hardening that
would result from cold forging, which would increase the difficulty
of performing secondary machining operations on the piece. Also,
while work hardening may be desirable in some circumstances, other
methods of hardening the piece, such as heat treating, are
generally more economical and more controllable. Alloys that are
amenable to precipitation hardening, such as most aluminum alloys
and titanium, can be hot forged, followed by hardening.
Production forging involves significant capital expenditure for
machinery, tooling, facilities and personnel. In the case of hot
forging, a high-temperature furnace (sometimes referred to as the
forge) is required to heat ingots or billets. Owing to the size of
the massive forging hammers and presses and the parts they can
produce, as well as the dangers inherent in working with hot metal,
a special building is frequently required to house the operation.
In the case of drop forging operations, provisions must be made to
absorb the shock and vibration generated by the hammer. Most
forging operations use metal-forming dies, which must be precisely
machined and carefully heat-treated to correctly shape the
workpiece, as well as to withstand the tremendous forces involved.
There are many different kinds of forging processes available;
however, they can be grouped into three main classes:
Drawn out: length increases, cross-section decreases
Upset: length decreases, cross-section increases
Squeezed in closed compression dies: produces multidirectional flow
Common forging processes include: roll forging, swaging, cogging,
open-die forging, impression-die forging, press forging, automatic
hot forging and upsetting.
Forging Materials and applications
Forging of steel
Depending on the forming temperature steel forging can be divided
A Hot forging of steel
1. Forging temperatures above the recrystallization temperature
between 950–1250 °C
2. Good formability
3. Low forming forces
4. Constant tensile strength of the workpieces
B Warm forging of steel
1. Forging temperatures between 750–950 °C
2. Less or no scaling at the workpiece surface
3. Narrower tolerances achievable than in hot forging
4. Limited formability and higher forming forces than for hot
5. Lower forming forces than in cold forming
C Cold forging of steel
1. Forging temperatures at room conditions, self-heating up to 150
°C due to the forming energy
2. Narrowest tolerances achievable
3. No scaling at workpiece surface
4. Increase of strength and decrease of ductility due to strain
5. Low formability and high forming forces are necessary
For industrial processes steel alloys are primarily forged in hot
condition. Brass, bronze, copper, precious metals and their alloys
are manufactured by cold forging processes, while each metal
requires a different forging temperature.
WHAT DO WE OFFER?
We are the forging parts solutions provider. The types of forgings
we produce can range from a fraction of 0.5 pound up to 350 lbs.
Our capabilities in materials include multiple grades and types of
metals, depending on the end use. Carbon, alloy and stainless
steels, as well as aluminum, brass and titanium can all be forged.
We also offer a range of additional services, allowing us to stay
competitive and directly supply finished product to our customers.
WHY Choose US?
We are a comprehensive forging solutions provider committed to
excellence in everything we do. In addition, we are ISO 9001
certified. Our engineering team utilizes various computer modeling
techniques and the latest technological capabilities, as well as
extensive physical testing. We offer our partners a dependable link
in their supply chain by constantly focusing on quality, short lead
times and competitive pricing. Each forging, no matter how complex,
is also backed by our ongoing customer service and expert