When to Forge or Machine
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When your application requires a new or replacement part, there are a few metalworking processes to choose from. Each offers a unique set of pros and cons, depending on your needs, so it is important to understand your options.
Review the guide below for a better idea of when to forge and when to machine:
Forging offers many unique advantages when compared to machining, especially in demanding industrial applications. If you are worried about your parts failing prematurely, or your application requires maximum strength and durability, forging is likely better suited to your needs.
Forging provides a higher level of structural integrity than any other metalworking process. By eliminating structural voids that can weaken parts, forging provides a level of uniformity to help maximize part performance.
During machining, grain ends are exposed, making parts more susceptible to weakening and cracking. Forging refines and strengthens parts by keeping the grain flow intact, helping to strengthen transition points and prevent premature failures.
Because it requires less starting material to create a forged part, open-die forging can help reduce waste and material costs. When you turn a product from bar, the corner stock is lost, but you are still required to pay for the excess material. With open-die forging, your part is shaped by the dies, significantly reducing material waste.
While forging offers many advantages in part strength and longevity, it is not necessary for many lower-impact applications. If your parts will not be subject to ongoing wear and tear, machining will likely be an effective and affordable solution for your needs.
In lower-impact applications, strong transition points are likely not your top priority. Parts machined from bar are typically sufficient if you are planning to use your parts in less demanding environments.
Forging can be a pricier alternative to machining, and although it offers many benefits, these benefits might not outweigh the costs in some situations. If the longevity and material savings from forging do not compensate for the price tag, machining might make more sense for your application.
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Not sure what we mean by open-die forging? You are not alone. Open-die forging is a process of shaping steel without the use of part-specific dies, allowing for complete customization. Forging is one of the best ways to create durable metal parts, built to stand up to tough industrial applications.
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Whether forging or machining is best suited to your needs, Solmet has the skills, equipment and capabilities to take on your next project. Request a quote using the form below to get started.
When it comes to manufacturing metal parts, it is crucial to consider all the different variables that are needed to ensure that you are making the right decision. Each manufacturing process is a viable option, and so it all depends on so many factors ' especially where and what it is for, the amount, and its total cost. In the case of rigging products, 'Which one is better? Steel forgings or machined forgings?' is the question that has been asked so many times by clients. If you're wondering the same thing, keep reading to find out the pros and cons.
Forging is the process of forming material into a solid state, typically by heating the metal first to make it malleable and then hammering or pressing it to create a specific shape. Machining is a term that is typically a computerized process that passes a piece of metal into the machining tool. It is used to remove excess metal from raw materials. Most forging and casting processes result in dimensions and surface conditions that will still require machining to achieve the desired dimension and shape.
Machining is convenient for producing pieces of complicated and acute-angled shapes. It is suitable and cost-effective for one-time production and for those who are not aiming for mass production output. Some forgings also use machines for surface finishes to cast molds for their forging presses due to pre-program accuracy.
Forging is the perfect option if you need to make thousands of replicas of the same molded piece of metal. It offers uniformity of composition and structure. Forging results in metallurgical recrystallization and grain. The tight grain structure of forging offers great wear resistance without the need to make products harder than they are.
Machining can take a while, as opposed to forging, which can produce basic parts easily and quickly. The true expense, however, is in the amount of waste produced when metal is removed from each fabrication that results in shavings that can only be sold for scraps.
With forging, you may need to perform several secondary processes to achieve the desired outcome. Forging sizes are limited due to the size of the press.
Ask yourself how strong and detailed you need your product to be. While machining is probably the most useful alternative in a wider variety of situations, forging is the way to go if you're looking for a stronger and tactile production.
At Ferralloy Inc., we guarantee that the products you purchase are manufactured by industries that prioritize quality. Schedule an appointment today with our team if you are still unsure which manufacturing process is right for you.
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