Metal forging is a versatile metalworking process that uses heat and localized compressive forces to shape a metal workpiece. While the process originated several centuries ago, developments in engineering, machinery, and metallurgy have made forging one of the most effective metalworking techniques available today. The process is compatible with a range of steel alloys and can create everything from small mechanical parts to larger structural components for transportation equipment.
01Recycled Scrap
02Melting & Pouring
03Rolling Steel
04Cutting Billet
05Forging
06Heat Treatment
07Final Inspection & Testing
08Product Use
09End of Life Collection
10Recycling Process
01
Step 01
Recycled Scrap
Many metals can be recycled without losing strength which contributes to sustainable manufacturing practices.
02
Step 02
Melting & Pouring
The metal becomes very hot and pliable but remains solid.
03
Step 03
Rolling Steel
Taking the melted/molten steel into a mold allowing it to be shaped to meet the design needs for the product being manufactured.
04
Step 04
Cutting Billet
Created by continuous casting, or hot rolling.
Once the billet is in the initial form and size, it may be shaped into the final part form via methods like CNC machining
05
Step 05
Forging
Once planning and toolmaking have been completed, the actual metalworking can begin. First, the billet, or workpiece needs to be cut to size. Once cut, it must then be heated to the proper temperature. Once heated, the billet is ready to be formed by forging.
Depending on the application, the casting (billet or steel casting) is then hammered, pressed between dies, or pushed into a mold to change its shape.
Cold forging is another method in which metal is hammered or shaped without being heated.
Forging relies on the use of dies to compress and shape metal, so it’s critical to determine what set of tools will be most effective to achieve the desired shape.
06
Step 06
Heat Treatment
Heat treatment helps to relieve internal stresses, refine grain structure, and improve and alter mechanical and physical properties
Methods include:
- Annealing
- Normalizing
- Quenching
- Tempering
07
Step 07
Final Inspection & Testing
Cornell forge will complete a thorough quality check of the forged products to ensure they meet the specifications provided by the customer.
We will make corrections if needed to meet customer expectations.
08
Step 08
Product Use
Customers get their forged products to use in their industry.
Industries Cornell Forge supports include:
- Agriculture
- Off-highway
- Hand tools
- Marine
- Oil
- Recreational
- Rail
- Firearms & Defense
- Construction
- Forestry
- Gear Box
- Forged Truck Components
- Mining
09
Step 09
End of Life Collection
Once your forged product has served its purpose and is at the end of its life, it will be collected to be recycled.
Products are often separated by material, treatment, etc. and are then broken up/compacted for easier handling.
The fragments are melted and remolded into varying sizes.
Once solidified, the metal will need to quality checked to ensure it can again enter the market as a raw material
10
Step 10
Recycling Process
The process starts all over with quality-checked material.