Drop and Horizontal Forging Machines

Definition

Forging machines are heavy-duty industrial presses used to shape metal through compressive forces. A Drop Forging Machine uses gravity or power to drop a heavy ram onto a workpiece to force metal into a die cavity. A Horizontal Forging Machine (often called an Upsetting Machine) acts like a press that moves horizontally to compress the end of a bar or rod to increase its cross-sectional area.

Main Content

1. Drop Forging Machines

These machines utilize a "ram" that is lifted and then dropped onto the workpiece.
The energy for deformation comes from the kinetic energy of the falling ram, which is usually controlled by steam, air pressure, or gravity.

2. Horizontal Forging Machines (Upsetters)

These are specifically designed for "upsetting," which is the process of increasing the cross-section of a bar at the expense of its length.
The machine features a stationary die and a moving punch that acts in a horizontal plane.

3. Comparison of Operation

Drop forging is typically used for shaping complex parts like crankshafts or connecting rods where the metal must flow into intricate die shapes.
Horizontal forging is used for mass-producing fasteners, bolts, and valves where the metal is gathered at one end of a rod.

DROP FORGING (Vertical)      HORIZONTAL FORGING (Upsetting)
     |   |                         |  [Ram]  |
     |Ram|                         |  ---->  | [Die]
     |___|                         |_________|
       ||                             [Workpiece]
    [Workpiece]

Working / Process

1. Preparation of Stock

The raw metal billet is heated in a furnace to a temperature where it becomes plastic (malleable).
For horizontal forging, the bar is cut to a specific length before being fed into the machine.

2. Deformation

In drop forging, the ram strikes the workpiece multiple times, forcing it into the lower die impression.
In horizontal forging, the workpiece is gripped by two clamping dies, and a header punch strikes the protruding end to "upset" or widen the metal.

3. Finishing and Removal

Excess metal, known as "flash," is trimmed away in a secondary operation.
The finished part is removed from the die, often by mechanical ejectors, and allowed to cool.

Advantages / Applications

Strength and Durability: Forged parts have superior grain structure and mechanical properties compared to cast parts.
High Production Rates: Horizontal forging is exceptionally fast for high-volume manufacturing of bolts, studs, and engine valves.
Versatility: Drop forging is ideal for high-stress aerospace and automotive components like gears and connecting rods.

Summary

Drop and horizontal forging machines are critical metal-forming technologies that utilize compressive force to transform raw metal billets into high-strength, durable components. Drop forging excels in vertical, complex shaping through repeated impact, while horizontal forging specializes in upsetting the ends of rods for mass-produced parts.

Important terms to remember: Ram, Upsetting, Billet, Flash, and Die Cavity.