How to Measure Costs for Metal Forging

Many manufacturing operations use forged pieces in assembling products.

Forging is the process of shaping metal by "plastic deformation," which means changing the shape of an item permanently without breaking or fracturing it by applying great force. Metal is forged through several processes such as hammer or press forging. The process is generally used in manufacturing to make a part to be used in a finished product. For example, metal pieces for airplanes and automobiles are forged. There are several factors that affect the cost of forging a piece of metal.

Things You'll Need

• CAD program
• Engineering spec sheets
• Pricing guides from forging companies

Instructions

1. Create a CAD drawing or contract a design engineer to create a drawing of the desired piece. Analyze the construction of the piece. Work to identify areas where the piece can be simplified. Send the CAD file to the forging company to get input on how to make the piece less expensive to produce. Their engineers can identify challenges before the production process is started, saving money in the long run.

2. In consultation with the forging company, price the cost of creating a die, or mold, for the piece. The cost of forging is affected by what material is needed to construct the die and the complexity of the construction process. If the die is simple or is similar to other dies in use already, the cost will be lower. For a complex, unique or detailed die, the cost will be higher.

3. Using the engineering specifications sheet and working with a qualified forging company, determine the best alloy or metal for the piece needed. The material used to create the piece has an effect on the final cost. Nickel and its alloys have the highest price, followed closely by titanium. Significantly below those two in cost are copper and magnesium and their alloys, as well as stainless steel. Aluminum and zinc are the next highest-priced materials, with carbon steel, alloyed steels and cast iron being the least expensive material.

4. Consider precision forging, where the processes are refined so that the pieces produced are in nearly-final or nearly zero tolerance, limiting the need for additional work after the pieces are pressed. Look for refinements in the preheating, forging, descaling, lubrications and temperature control procedures. Although it may cost slightly more originally, precision forging means avoiding additional machining after forging. This can offset the higher upfront costs, particularly with large forging runs.

References

• Forging: How Are Forgings Produced
• JOM: Reducing Costs in Aircraft: The Metals Affordability Initiative Consortium
• Roymech: Useful Tables