- In Casting, “Hot liquid metal is poured into a die to get a die shape metal piece.”
- Forging, “It is the process in which heated metal is shaped with a compressive force in between the die. Which results die shape metal get obtained.”
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DROP FORGING HAMMER
It is not an easy task for a normal person to lift the 50 KGs with one hand. Some how if we assume that 1person can lift 50 Kgs. Than we need at least 20 men to lift 1 Ton.
But with help of drop hammer, 1TON weight can be uplift by 1 single person with only a single hand without any type of burden. That’s the Drop Forging hammer.
- Belt drop hammer
- Friction drop hammer
- Gravity drop hammer
As name implies, In this process Drop or free fall of big hammer is used to produce compressive force on heated metal in between the two dies at a particular temperature. The Induction motor is the key which generates the power behind the drop forging hammer. A motor continuously rotates on above the hammer. A special mechanical mechanism is used to lift the big hammer.
A mechanical mechanism is connected with a rope. When a rope is get pulled, due to the mechanism, big hammer get lifted. When rope is get released, hammer get fall due to gravity.
Features of drop forging hammer
- Capacity ranges from 500kgs to 10000kgs
- Both skilled & Non-skilled workforce can operate it
- Versatile in manufacturing forged products
- Spare parts are readily available
Parts of drop forging hammer
- Gear head Assembly
- Columns
- Anvil block
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1. Gear Head Assembly
2. Columns, slides & Tup
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The columns are locked with the help of tapered wedges of alloy steel to ensure firm alignment of columns which helps in accurate guiding of tup.
Tup is the heavy weight Which presses the heated metal in between the die. Tup is made out of EN-9 cast steel.
The clearance between the tup & guideways attached to column is maintained with the help of tapered wedges which brings the columns inward & outward.
Synthetic rubber mat is provided on the anvil block on which column rest. It dampens the induced vibration which increase the life of tup & columns & also ensure smooth working of machine for longer period.
3. Anvil Block
It is machined from top face to hold die holder firmly & maintain position of columns. The die holder fixed in the anvil block is forged from high grade alloy steel all over hardened & it is positioned properly with the help of alloy steel tapered wedges.
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Electrical part of Drop Forging Hammer
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Working of Drop Forging Hammer
Technical specifications of Drop Forging Hammer
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SUMMARY
- Forging is the process in which heated metal is shaped with a compressive force in between the die. Which results die shape metal get obtained.
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Drop forging hammer is also known As Belt drop hammer, Friction drop hammer & Gravity drop hammer.
- In Drop forging hammer, A heavy weight is lifted up through a mechanical arrangement & then gravity force is utilized to obtain compressive force.
- Drop forging hammers are rated in Tons, ranges from 0.5 ton to 10 ton.
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Machine is divided into three sections : Gear head Assembly, Columns & Anvil block.
🔧 Drop Forging Hammer — FAQs
1. What is a Drop Forging Hammer?
A drop forging hammer is a forging machine that shapes heated metal by lifting a heavy ram and then dropping it onto the workpiece between dies, using gravity and mechanical force.
2. How does a drop forging hammer work?
The hammer’s tup (ram) is lifted by a mechanical system driven by a motor and gear head assembly. When released, the ram falls under gravity and delivers a powerful blow to the heated metal placed between dies, forming it into the desired shape.
3. What are the main parts of a drop forging hammer?
Typical main sections include the gear head assembly, columns & slides, tup (ram), and the anvil block which holds the lower die.
4. What are the different types of drop forging hammers?
Drop forging hammers come in several forms including belt drop hammer, friction drop hammer, and gravity drop hammer, each using a slightly different lifting mechanism.
5. What materials are commonly forged using a drop forging hammer?
Metals like carbon steel, alloy steel, aluminum, and other alloys are typically forged using drop hammers to achieve stronger mechanical properties and desired shapes.
6. Why is the metal heated before drop forging?
Heating metal before forging makes it softer and more ductile so it can flow into the die cavities under compressive forces, allowing for better shaping with fewer defects.
7. What industries use drop forging hammers?
These machines are widely used in automotive, aerospace, railway, and agricultural equipment manufacturing for making parts like crankshafts, connecting rods, hooks, and levers.
8. What are the advantages of drop forging over casting?
Drop forging generally produces parts with better grain flow and strength, reduced internal defects, and superior mechanical properties compared to casting.
9. How is a drop forging hammer rated?
Hammers are rated by capacity, typically in tons, representing the weight and impact energy the machine can deliver — common sizes range from 0.5 to 10+ tons.
10. Is drop forging the same as press forging?
No. Drop forging uses high-speed blows to shape metal, while press forging applies slow, continuous pressure with a mechanical or hydraulic press.
11. How many blows are needed to form a part?
The number of blows depends on the complexity of the part, die shape, and material — often multiple blows are needed to fully fill the die and achieve final shape.
12. What safety precautions are important?
Operators need proper training, heat-resistant PPE, guarding around moving parts, and careful attention to avoid burns, flying scale, and pinch points when working with drop forging hammers. (General safety practice)
Hope, post is beneficial If You have any doubt, Query or suggestion Please Do comments !