Casting vs Forging
Casting:
Casting is a process in which molten metal flows by gravity or other force into a mold where it solidifies in the shape of the mold cavity
- The term casting also applies to the part made in the process
- Steps in casting seem simple:
- Melt the metal
- Pour it into a mold
- Let it freeze
Advantages of Casting:
- Can create complex part geometries
- Can create both external and internal shapes.
- Some casting processes are net shape*; others are near net shape.
- Can produce very large parts.
- Some casting methods are suited to mass production.
- Suitable for any metal that can be heated to a liquid.
Disadvantages of Casting:
- Limitations on mechanical properties.
- Poor dimensional accuracy and surface finish for some processes; e.g., sand casting.
- Safety hazards to workers due to hot molten metals.
- Environmental problems.
Forging:
Deformation process in which work is compressed between two dies using either impact or gradual pressure to form the part.
- Oldest of the metal forming operations, dating from about 5000 BC.
- Components: engine crankshafts, connecting rods, gears, aircraft structural components, jet engine turbine parts.
- Also, basic metals industries use forging to establish a basic form of large parts that are subsequently machined to final shape and size.
Classification of Forging Operations:
1. Hot or warm forging:
Most common, due to the significant deformation and the need to reduce strength and increase the ductility of work metal.2. Cold forging:
Advantage: increased strength that results from strain hardening. Cold forging is generally preferred when the metal is already a soft metal, like aluminum.Advantages of Forging:
- It produces a tougher product compare to other.
- The product made by forging has high impact or tensile strength.
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