Forging

Forging shapes solid metal by applying compressive forces, usually with a hammer, press, or dies. It can refine a component’s shape and strengthen its grain structure.

Open-die forging: A forging process that compresses metal between dies that do not fully enclose the workpiece. The workpiece can be repositioned between strokes, allowing large or simple shapes to be formed.
Plastic deformation: Permanent change in a material’s shape after stress exceeds its elastic limit. Forging depends on permanent deformation rather than temporary elastic bending.
Crankshaft: A rotating engine component that converts reciprocating piston motion into rotation. Forged crankshafts are used where cyclic loads demand strength and fatigue resistance.
Casting: A manufacturing process that forms a part by pouring molten material into a mold and letting it solidify. Unlike forging, casting shapes metal from a liquid rather than a solid workpiece.
Impression-die forging: A forging process that forces metal into shaped cavities in opposing dies. The die cavities guide metal flow toward a component’s detailed outline.
Yield strength: The stress at which a material begins to deform permanently. It helps determine the force required to start shaping a workpiece.
Connecting rod: An engine component that links a piston to a crankshaft. Forging produces connecting rods designed to withstand repeated tensile and compressive loads.
Machining: A manufacturing process that removes material from a workpiece using cutting tools. Machining removes stock, while forging redistributes it through deformation.
Drop forging: A forging method in which a hammer delivers repeated blows to shape metal in dies. Its repeated impacts are a common way to fill impression dies.
Recrystallization: Formation of new, relatively strain-free grains in a deformed material, typically during heating. During hot forging, recrystallization can replace elongated grains as deformation proceeds.

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