How Automotive Metal Forming Works

One of the most important things about metal is that it can undergo plastic deformation. That doesn't mean metal is made out of plastic, but it can do one of the things that plastics can: It literally can take on almost any shape that we can imagine.

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The process of deformation begins with a blank, a quantity of metal in some basic form that will undergo the change in shape. The blank becomes the workpiece -- the piece of metal to be reshaped -- in the metal forming process. For automotive metal forming, the blank is often made of sheet metal, which can be stamped, cut or bent into a shape needed for an automobile's body. Alternatively, it can be a solid block of metal in a cubical or lens-like shape. Here are some ways that a metal workpiece can be deformed during the automotive manufacturing process:

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Bending: In bending, force is applied to a sheet metal workpiece to produce a curvature of the surface. Bending is generally used to produce simple curved surfaces rather than complex ones. A mechanically operated press drives a punch against sheet metal, forcing it into a simple die with enough pressure to produce a permanent change in the metal's shape. The amount of pressure is important. If not enough pressure is applied, the metal can simply spring back into its original shape. If too much is applied, it can break.

Drawing: In drawing, the sheet metal is forced against a die that has been cut into the three-dimensional, often curved shape that the sheet metal is to take on. In effect, the die is used as a mold for the metal. This technique can produce relatively complex shapes. Once again, pressure is applied to the workpiece using a hydraulically or mechanically operated punch. There are a number of dangers involved, not so much to people (since the process is largely mechanized) but to the metal itself. It can crack from too much pressure or wrinkle from its interaction with the die. Lubricant can be used to make the metal slide more smoothly against the die, avoiding the possibility of wrinkling. Alternatively, the wrinkled edges can be trimmed from the metal in a separate operation. This method is commonly used to make auto body parts and fuel tanks.

Stamping: In stamping, a device called a stamping press is used with a series of dies to cut and form metal into various shapes. This is commonly used to make auto parts such as hubcaps and fenders.

Extrusion: Extrusion can be used to produce long metal objects, such as rods and tubes. The metal workpiece is forced into a die with a hole in the opposite end. The metal is extruded through the hole to form the shape. Extrusion can be used to manufacture important parts of a car's drive train or the anchors that hold seatbelts in place.

Forging: The forging process uses a hammer or press that is essentially a mechanized version of the hammers used by ancient blacksmiths. The metal is hammered against a surface that serves as an anvil. It can be hammered repeatedly so as to form complex shapes. This can be used as an alternative to the drawing process.

The above processes are generally used with cold metal. Hot metal can also be used, sometimes at high enough temperatures that the molten metal can be poured into a die. This requires very expensive dies that can withstand the heat and must be done quickly, to minimize the exposure of the die to the molten metal.

On the next page we'll look at how modern metal forming technologies are moving auto manufacturing into the future.

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The automotive industry is one of the most demanding and competitive sectors in the world, requiring high-quality, durable, and reliable components for various applications. One of the methods that can produce such parts is forging, a process that involves shaping metal using compressive forces at high temperatures. Forging can create parts that are stronger, lighter, and more resistant to wear and tear than other methods, such as casting or machining.

In this blog post, we will explore the basics of forging, the most common materials used in forging auto parts, the different forging processes used in making automotive forging parts, and some examples of automotive forged metals parts. We will also discuss the benefits and challenges of forging for the automotive industry, and how it can contribute to automotive excellence.

Overview of Forging Metal Parts

Forging is a metalworking process that dates back to ancient times, when blacksmiths used hammers and anvils to shape metal into tools and weapons. Today, forging is done using sophisticated machines and equipment that can apply precise and controlled forces to metal at high temperatures, ranging from 900°C to °C.

Forging can be classified into two main categories: hot forging and cold forging. Hot forging is done at temperatures above the recrystallization point of the metal, which allows the metal to deform plastically without cracking or breaking. Cold forging is done at temperatures below the recrystallization point of the metal, which increases the strength and hardness of the metal, but also requires more force and energy.

Forging can also be classified according to the degree of contact between the metal and the dies (the tools that shape the metal). There are three main types of forging: open die forging, closed die forging, and roll forging. Open die forging is done by placing the metal between two flat or contoured dies that do not enclose the metal completely, allowing the metal to flow freely in some directions. Closed die forging is done by placing the metal in a cavity formed by two or more dies that completely enclose the metal, creating a near-net-shape part with minimal waste. Roll forging is done by passing the metal through two or more rotating rolls that reduce the thickness and increase the length of the metal.

Most Common Materials Used in Forging Metal Parts for Auto

The choice of material for forging auto parts depends on several factors, such as the desired properties, performance, cost, availability, and environmental impact of the material. Some of the most common materials used in forging auto parts are:

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Aluminium

Aluminium is a lightweight, corrosion-resistant, and recyclable material that can be forged into various shapes and sizes. Aluminium forgings are widely used in automotive applications, such as wheels, suspension components, engine parts, chassis parts, and body panels. Aluminium forgings can offer advantages such as reduced weight, improved fuel efficiency, lower emissions, increased safety, and enhanced aesthetics.

Steel

Steel is a strong, durable, and versatile material that can be forged into complex and intricate shapes. Steel forgings are commonly used in automotive applications that require high strength, toughness, wear resistance, and fatigue resistance, such as crankshafts, connecting rods, gears, axles, bearings, and pistons. Steel forgings can offer advantages such as increased performance, reliability, durability, and longevity.

Process Used in Making Automotive: Forging Metal Parts

The choice of forging process for making automotive forging parts depends on several factors, such as th e type of material, the shape and size of the part, the production volume, the quality requirements, and the cost considerations. Some of the most common forging processes used in making automotive forging parts are:

Closed Die Forging

Closed die forging is a process that involves placing a preheated metal billet (a semi-finished piece of metal) in a cavity formed by two or more dies that completely enclose the metal. The dies are then pressed together with high force, causing the metal to fill the cavity and take the shape of the dies. The excess metal is squeezed out through flash lines (gaps between the dies), which are later trimmed off. Closed die forging can produce near-net-shape parts with high dimensional accuracy, surface finish, and mechanical properties. Closed die forging is suitable for producing complex and intricate shapes with fine details, such as gears, valves, and flanges. Closed die forging is also suitable for producing high-volume parts with consistent quality and low scrap rate.

Open-Die Forging

Open-die forging is a process where the metal part is heated and placed between two flat or contoured dies that are not completely closed. The dies hammer or press the metal part until it reaches the desired shape and size. Open-die forging is suitable for producing large and simple parts such as shafts, rings, and cylinders. Open-die forging can also be used to pre-form the metal part before it undergoes another forging process.

Differences Between Open-Die and Closed-Die Forging

One of the main differences between open-die and closed-die forging is the shape and size of the dies used in the process. Open-die forging uses flat or contoured dies that do not completely enclose the metal, while closed-die forging uses dies that have a cavity or impression that matches the shape of the part.

Another difference is the dimensional accuracy and surface finish of the forged parts. Open-die forging produces parts with low dimensional accuracy and surface finish, as the metal is free to flow in all directions. Closed-die forging produces parts with high dimensional accuracy and surface finish, as the metal is confined within the die cavity. A third difference is the complexity and cost of the forging process. Open-die forging is simpler and cheaper than closed-die forging, as it requires less tooling and machining. However, open-die forging is limited by the size and shape of the hammer and anvil and cannot produce complex parts. Closed-die forging is more complex and expensive than open-die forging, as it requires more tooling and machining. However, closed-die forging can produce complex parts with intricate details and features.

Roll Forging

Roll forging is a process that involves passing a preheated metal billet through two or more rotating rolls that reduce the thickness and increase the length of the metal. The rolls can have flat or grooved surfaces that impart the desired shape and profile to the metal.

Roll forging can produce parts with uniform cross-sections and smooth surfaces. Roll forging is suitable for producing simple and symmetrical shapes with long lengths, such as bars, rods, and shafts. Roll forging is also suitable for producing low-to-medium volume parts with low tooling cost and high productivity.

Upset Forging

This process uses a press or a hammer to increase the diameter of a metal rod or bar by reducing its length. The metal is heated to a high temperature and then placed between two flat dies. The dies are then moved towards each other to compress the metal radially. Upset forging is suitable for producing parts with large heads or flanges, such as bolts, screws, and rivets.

Automotive Forged Metal Parts

Some examples of automotive forged metals parts are:

Crankshafts: Crankshafts are the main rotating components of an engine that convert the linear motion of the pistons into rotational motion. Crankshafts are usually forged from steel or alloy steel, as they require high strength, toughness, wear resistance, and fatigue resistance. Forged crankshafts can offer advantages such as improved performance, reliability, durability, and longevity.

Connecting Rods: Connecting rods are the components that connect the pistons to the crankshafts. Connecting rods are usually forged from steel or aluminium, as they require high strength, light weight, and stiffness. Forged connecting rods can offer advantages such as reduced weight, improved fuel efficiency, lower emissions, increased safety, and enhanced aesthetics.

Gears: Gears are the components that transmit power and motion between different parts of a vehicle, such as the engine, transmission, differential, and wheels. Gears are usually forged from steel or alloy steel, as they require high strength, hardness, wear resistance, and noise reduction. Forged gears can offer advantages such as increased performance, reliability, durability, and longevity.

Steering knuckles: These are the parts that connect the steering system to the suspension system. They are responsible for transferring the steering force to the wheels, so they need to be rigid and reliable.

Conclusion

Forging is a metalworking process that can produce high-quality, durable, and reliable parts for various automotive applications. Forging can create parts that are stronger, lighter, and more resistant to wear and tear than other methods, such as casting or machining. Forging can also contribute to automotive excellence by offering benefits such as reduced weight, improved fuel efficiency, lower emissions, increased safety, and enhanced aesthetics. Forging is a process that involves shaping metal using compressive forces at high temperatures. Forging can be classified into two main categories: hot forging and cold forging. Forging can also be classified according to the degree of contact between the metal and the dies: open die forging, closed die forging, and roll forging. Some of the most common materials used in forging auto parts are aluminium and steel. Some of the most common forging processes used in making automotive forging parts are closed die forging and roll forging. Some examples of automotive forged metals parts are crankshafts, connecting rods, and gears.

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