How can you reduce scrap rate in forging?

1 Choose the right material

The type and quality of the material you use for forging can affect the scrap rate. Some materials are more prone to cracking, warping, or oxidation than others. For example, high-carbon steel is harder to forge than low-carbon steel, and aluminum alloys are more sensitive to temperature changes than copper alloys. You should choose a material that suits your product specifications, forging equipment, and operating conditions. You should also ensure that the material is free of defects, impurities, or contaminants that can compromise its performance or appearance.

2 Optimize the design

The design of the part you want to forge can also influence the scrap rate. You should aim for a design that minimizes the amount of material required, reduces the number of forging operations, and simplifies the shape and geometry of the part. You should also consider the tolerances, dimensions, and surface finish of the part, and avoid features that are difficult or impossible to forge, such as sharp corners, thin walls, or complex curves. You can use software tools, such as CAD or FEA, to help you optimize the design and simulate the forging process.

3 Control the temperature

The temperature of the material and the forging equipment is another critical factor that affects the scrap rate. The temperature determines the flow and deformation of the material, as well as the formation of scale and oxide layers. If the temperature is too high, the material can melt, burn, or lose strength. If the temperature is too low, the material can crack, fracture, or harden. You should monitor and regulate the temperature of the furnace, the dies, and the material throughout the forging process. You should also use lubricants, coatings, or protective atmospheres to prevent oxidation and scaling.