Hot / Steel Forging is a metal shaping process involving heat and compressive forces. The hot / Steel Forging Process includes heating, shaping with dies, cooling, trimming, and finishing. It is commonly used to manufacture custom parts like Crankshafts, connecting rods, gears, and axles. Our advanced forging cost estimating and calculating tool, and model provide reliable pricing information. With our comprehensive forging cost analysis on Costing Expert, you can understand the true cost to forge parts, optimize your manufacturing expenses, and control your BOM (bill of material) production costs. Whether you need to calculate the forging unit cost, forging part cost, or overall manufacturing cost, our specialized tools have got you covered. Compare forging costs, analyze pricing strategies, and enhance profitability with our efficient forging cost optimization solutions. Get accurate insights into your forged part and product cost, ensuring competitive pricing and cost-effective manufacturing.

A) General Part Information

Part Number:-

- Part Number which is usually mentioned on the drawing. (Alphanumeric values are accepted).

Part Description:-

- Part Name, yoke, crankshaft LH/RH, etc. (Alphanumeric values are accepted).

Annual Volume:-

- The Number of Pieces that are Required in a Year (1- 10000000 Nos).

Lot Run Size:-

- The Number of Parts to be Processed in a Single Setup (Less than or equal to Annual volume).

B) Part Design Information

Complexity:- Select part designs as per its shape from the dropdown.

Circular Simple:-

i)Part with Round Shape like Gear blanks, Washer, Rings etc.

Medium:-

ii)Part Round in shape with a slight profile- eg: Gear,Flange.

Complex:-

iii)Part have round shape with deep stem or design eg: CV outer.

Part Shape:- Select part designs as per its shape from the dropdown.

Non-Circular Part:-

i)Part with simple Shape like rectangular, square, with les depth, assisting easy material flow and dimensional constraints. eg: Trunion Pin, Lever, Mounting Bearing, etc.

Circular Parts:-

ii)Part irregular in shape with a slight profile- eg: Clamp, Spider/Cross, Yoke, Rocker arm etc.

Part Max Dimension (Outside diameter/Length):-

-Maximum Length or Outside diameter of the part. Length: length would be for non circular parts. Enter Length or Outside diameter of the part. length as per part drawing (min 1 to 1000 mm). Outside diameter: Enter Outer Diameter dimension for Circular Parts (min 1 mm to 500mm).

Part Min Dimension (Outside diameter/Width):-

- Minimum Length / Width or Outside diameter of the part. Width: Width would be for non circular parts. Enter width or min lateral dimension of the part. Width as per part drawing (min 1 to 1000 mm) Outside diameter: Enter Outer Diameter dimension for Circular Parts (min 1 mm to 500mm).

C) General Part Information:

Part Net Weight (kg):-

- Final Weight of the part. Permitted range is 1KG – 20KG.

Gross Weight (Kg):-

- Weight of the part before processing. Permitted range is 1gm – 25kg, after adding net weight gross weight is auto calculated also. If user needs to override it can add manually into the input box. Estimated gross weight is given from the Net weight you have provided, the user can override it if needed.

Cut Piece Diameter (mm):-

- Enter the Cross sectional distance of the billet bar to enter Diameter of the part. (min 1 to 150 mm), after adding net weight cut piece diameter is auto calculated also. If user needs to override it can add manually into the input box. Estimated Cut Piece Billet Diameter is given, the user can override it if needed.

Cut Length mm:-

- Use override calculated cut length. Permitted range is 1-1000 mm, after adding net weight cut length is auto calculated also. If user needs to override it can add manually into the input box. Estimated Cut Piece Billet Length is given, the user can override it if needed.

D) Press Information

Estimated tonnage is provided as per inputs given by the user, also user can select appropriate tonnage from the dropdown if necessary.

Selected Press Tonnage :-

- As per part size and select appropriately. This tool calculates value for below tonnage range (630, 1000,1300,1600,2000, 2500,3500,4000) & also tool auto calculates the tonnage and selecting nearby higher tonnage as per automation, if user need to override it can add manually into input box. We have added 20 % Factor of safety to the tonnage calculation, we then round up to the most common press size available in market price.)

Press Tonnage	Diameter (Max)	Length (Max)
630	75	53
1000	100	70
1300	120	84
1600	140	98
2000	170	120
2500	210	210
3500	280	280
4000	320	320

E) Process Information

All processes are selected default to YES, user can override from the dropdown, if there is no need for the processes please select NO. But some processes are compulsory, so they can not be changed.

Select processes which are involved in operation & Unselect Process Which is not applicable:-

• Incoming Material Inspection :- Raw material steel bars comes with various grades with different Chemical & Mechanical Properties. Hence, depending on the type of raw material used, the process is designed.
For Expert/Buyer Validation limit
Pcs/Hour : 1-10000
Direct labour rate/Hr : 1 to 100
No of Operator : 0-5
Burden Rate – 1 - 10000
Process eff - 1-100%

• Billet Cutting :- Final Forged part has different dimensions with different material weights. Hence, depending on it, the billet diameter, billet cut length or cut weight is defined.
For Expert/Buyer Validation limit
Pcs/Hour : 1-10000
Direct labour rate/Hr : 1 to 100
No of Operator : 0-5
Burden Rate – 1 - 10000
Process eff - 1-100%

• Billet Heating:- Depending on the Billet cut weight / Length, heating cycle time is set along speed and power for heating. The induction Heater or Furnace capacity impacts the heating time of billet (Min- 3 sec to Max 60 sec)
For Expert/Buyer Validation limit
Pcs/Hour : 1-10000
Direct labour rate/Hr : 1 to 100
No of Operator : 0-5
Burden Rate – 1 - 10000
Process eff - 1-100%

• Reducer Rolling :- Rolling is done to reduce the cross section or undergoes change in the cross section. Facilitates forging process and loss of material as scrap
For Expert/Buyer Validation limit
Pcs/Hour : 1-10000
Direct labour rate/Hr : 1 to 100
No of Operator : 0-5
Burden Rate – 1 - 10000
Process eff - 1-100%

• Forging :- Press forging is a method of forming a piece of metal into a specific shape by applying gradual pressure on a shaped die holding the metal.
For Expert/Buyer Validation limit
Pcs/Hour : 1-10000
Direct labour rate/Hr : 1 to 100
No of Operator : 1-10
Burden Rate – 1 - 10000
Process eff - 1-100%

• Trimming :- Unwanted/ Excess material known as “Flash” which squirts out of the cavity as a thick ribbon of metal while forging.
For Expert/Buyer Validation limit
Pcs/Hour : 1-10000
Direct labour rate/Hr : 1 to 100
No of Operator : 1-5
Burden Rate – 1 - 10000
Process eff - 1-100%

• Piercing :- For removing unwanted material which is generally in the form of circle, piercing operation is done.
For Expert/Buyer Validation limit
Pcs/Hour : 1-10000
Direct labour rate/Hr : 1 to 100
No of Operator : 1-5
Burden Rate – 1 - 10000
Process eff - 1-100%

• Hot Padding :- Hot padding is done in order to achieve the required fine dimension.
For Expert/Buyer Validation limit
Pcs/Hour : 1-10000
Direct labour rate/Hr : 1 to 100
No of Operator : 1-5
Burden Rate – 1 - 10000
Process eff - 1-100%

• Heat Treatment :- Forging usually produces lot of stresses in material due to disturbance in grain structure alignment and hence must to be operated by some heating methods to its critical temperature in order to bring uniformity in structure.
For Expert/Buyer Validation limit
Pcs/Hour : 1-10000
Direct labour rate/Hr : 1 to 100
No of Operator : 1-5
Burden Rate – 1 - 10000
Process eff - 1-100%

• Shotblasting :- Shot Blasting is a surface treatment process using high velocity steel abrasive.
For Expert/Buyer Validation limit
Pcs/Hour : 1-10000
Direct labour rate/Hr : 1 to 100
No of Operator : 1-5
Burden Rate – 1 - 10000
Process eff - 1-100%

• Cold Pressing/Coining :- Cold Pressing/ Coining is done in order to achieve the required fine dimension like thickness, straightness.
For Expert/Buyer Validation limit
Pcs/Hour : 1-10000
Direct labour rate/Hr : 1 to 100
No of Operator : 1-5
Burden Rate – 1 - 10000
Process eff - 1-100%

• MPI Crack inspection :- Magnetic Particle Inspection (MPI) is a very effective method for location of surface breaking and slight sub-surface defects such as cracking, pores, cold lap, lack of sidewall fusion in welds etc. in magnetic materials.
For Expert/Buyer Validation limit
Pcs/Hour : 1-10000
Direct labour rate/Hr : 1 to 100
No of Operator : 1-5
Burden Rate – 1 - 10000
Process eff - 1-100%

• Inspection :- Final Inspection is simply relates to Quality Control. Quality Assurance plays a vital role & covers all activities from design, development, production, installation, servicing and documentation.
For Expert/Buyer Validation limit
Pcs/Hour : 1-10000
Direct labour rate/Hr : 1 to 100
No of Operator : 1-5
Burden Rate – 1 - 10000
Process eff - 1-100%

• Rust Preventive Oiling :- Rust preventive oil is applied by dipping, spray brush or circulation.
For Expert/Buyer Validation limit
Pcs/Hour : 1-10000
Direct labour rate/Hr : 1 to 100
No of Operator : 1-5
Burden Rate – 1 - 10000
Process eff - 1-100%

F) Add Additional process :-
- If user need to add any process / operation which is not mentioned in above section then simply click on “Add additional process” and then one process will be added and after giving inputs to the same process user can get the cost for part to be forged.

Hot/Steel Forging

Hot/Steel Forging Costing Tool

A) General Part Information

Part Number:-

- Part Number which is usually mentioned on the drawing. (Alphanumeric values are accepted).

Part Description:-

- Part Name, yoke, crankshaft LH/RH, etc. (Alphanumeric values are accepted).

Annual Volume:-

- The Number of Pieces that are Required in a Year (1- 10000000 Nos).

Lot Run Size:-

- The Number of Parts to be Processed in a Single Setup (Less than or equal to Annual volume).

B) Part Design Information

Complexity:- Select part designs as per its shape from the dropdown.

Circular Simple:-

i)Part with Round Shape like Gear blanks, Washer, Rings etc.

Medium:-

ii)Part Round in shape with a slight profile- eg: Gear,Flange.

Complex:-

iii)Part have round shape with deep stem or design eg: CV outer.

Part Shape:- Select part designs as per its shape from the dropdown.

Non-Circular Part:-

i)Part with simple Shape like rectangular, square, with les depth, assisting easy material flow and dimensional constraints. eg: Trunion Pin, Lever, Mounting Bearing, etc.

Circular Parts:-

ii)Part irregular in shape with a slight profile- eg: Clamp, Spider/Cross, Yoke, Rocker arm etc.

Part Max Dimension (Outside diameter/Length):-

-Maximum Length or Outside diameter of the part. Length: length would be for non circular parts. Enter Length or Outside diameter of the part. length as per part drawing (min 1 to 1000 mm). Outside diameter: Enter Outer Diameter dimension for Circular Parts (min 1 mm to 500mm).

Part Min Dimension (Outside diameter/Width):-

- Minimum Length / Width or Outside diameter of the part. Width: Width would be for non circular parts. Enter width or min lateral dimension of the part. Width as per part drawing (min 1 to 1000 mm) Outside diameter: Enter Outer Diameter dimension for Circular Parts (min 1 mm to 500mm).

C) General Part Information:

Part Net Weight (kg):-

- Final Weight of the part. Permitted range is 1KG – 20KG.

Gross Weight (Kg):-

Cut Piece Diameter (mm):-

Cut Length mm:-

- Use override calculated cut length. Permitted range is 1-1000 mm, after adding net weight cut length is auto calculated also. If user needs to override it can add manually into the input box. Estimated Cut Piece Billet Length is given, the user can override it if needed.

D) Press Information

Estimated tonnage is provided as per inputs given by the user, also user can select appropriate tonnage from the dropdown if necessary.

Selected Press Tonnage :-

E) Process Information

All processes are selected default to YES, user can override from the dropdown, if there is no need for the processes please select NO. But some processes are compulsory, so they can not be changed.

Select processes which are involved in operation & Unselect Process Which is not applicable:-

• Trimming :- Unwanted/ Excess material known as “Flash” which squirts out of the cavity as a thick ribbon of metal while forging. For Expert/Buyer Validation limit Pcs/Hour : 1-10000 Direct labour rate/Hr : 1 to 100 No of Operator : 1-5 Burden Rate – 1 - 10000 Process eff - 1-100%

• Piercing :- For removing unwanted material which is generally in the form of circle, piercing operation is done. For Expert/Buyer Validation limit Pcs/Hour : 1-10000 Direct labour rate/Hr : 1 to 100 No of Operator : 1-5 Burden Rate – 1 - 10000 Process eff - 1-100%

• Hot Padding :- Hot padding is done in order to achieve the required fine dimension. For Expert/Buyer Validation limit Pcs/Hour : 1-10000 Direct labour rate/Hr : 1 to 100 No of Operator : 1-5 Burden Rate – 1 - 10000 Process eff - 1-100%

• Shotblasting :- Shot Blasting is a surface treatment process using high velocity steel abrasive. For Expert/Buyer Validation limit Pcs/Hour : 1-10000 Direct labour rate/Hr : 1 to 100 No of Operator : 1-5 Burden Rate – 1 - 10000 Process eff - 1-100%

• Cold Pressing/Coining :- Cold Pressing/ Coining is done in order to achieve the required fine dimension like thickness, straightness. For Expert/Buyer Validation limit Pcs/Hour : 1-10000 Direct labour rate/Hr : 1 to 100 No of Operator : 1-5 Burden Rate – 1 - 10000 Process eff - 1-100%

• Rust Preventive Oiling :- Rust preventive oil is applied by dipping, spray brush or circulation. For Expert/Buyer Validation limit Pcs/Hour : 1-10000 Direct labour rate/Hr : 1 to 100 No of Operator : 1-5 Burden Rate – 1 - 10000 Process eff - 1-100%

F) Add Additional process :- - If user need to add any process / operation which is not mentioned in above section then simply click on “Add additional process” and then one process will be added and after giving inputs to the same process user can get the cost for part to be forged.

• Trimming :- Unwanted/ Excess material known as “Flash” which squirts out of the cavity as a thick ribbon of metal while forging.
For Expert/Buyer Validation limit
Pcs/Hour : 1-10000
Direct labour rate/Hr : 1 to 100
No of Operator : 1-5
Burden Rate – 1 - 10000
Process eff - 1-100%

• Piercing :- For removing unwanted material which is generally in the form of circle, piercing operation is done.
For Expert/Buyer Validation limit
Pcs/Hour : 1-10000
Direct labour rate/Hr : 1 to 100
No of Operator : 1-5
Burden Rate – 1 - 10000
Process eff - 1-100%

• Hot Padding :- Hot padding is done in order to achieve the required fine dimension.
For Expert/Buyer Validation limit
Pcs/Hour : 1-10000
Direct labour rate/Hr : 1 to 100
No of Operator : 1-5
Burden Rate – 1 - 10000
Process eff - 1-100%

• Shotblasting :- Shot Blasting is a surface treatment process using high velocity steel abrasive.
For Expert/Buyer Validation limit
Pcs/Hour : 1-10000
Direct labour rate/Hr : 1 to 100
No of Operator : 1-5
Burden Rate – 1 - 10000
Process eff - 1-100%

• Cold Pressing/Coining :- Cold Pressing/ Coining is done in order to achieve the required fine dimension like thickness, straightness.
For Expert/Buyer Validation limit
Pcs/Hour : 1-10000
Direct labour rate/Hr : 1 to 100
No of Operator : 1-5
Burden Rate – 1 - 10000
Process eff - 1-100%

• Rust Preventive Oiling :- Rust preventive oil is applied by dipping, spray brush or circulation.
For Expert/Buyer Validation limit
Pcs/Hour : 1-10000
Direct labour rate/Hr : 1 to 100
No of Operator : 1-5
Burden Rate – 1 - 10000
Process eff - 1-100%

F) Add Additional process :-
- If user need to add any process / operation which is not mentioned in above section then simply click on “Add additional process” and then one process will be added and after giving inputs to the same process user can get the cost for part to be forged.