Forging Process Sheet Template
A forging process sheet tells the floor how a part is made, in order, with the settings that matter. It is the paper that connects the die, the press and the heat treat step to one part number. Use this template to start a consistent sheet for each part.
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Forging Process Sheet Template
Forging Process Sheet
Company: Ridgeway Forgings Part number: FG-30412 Revision: C Material: AISI 4140 bar, ASTM A29
Setup Data
Process: Closed die hot forging Billet: 75 mm round x 190 mm, 6.5 kg Forging temperature: 1150 to 1250 deg C Equipment: 1600 tonne mechanical press Die set: DS-30412-02 Post forge treatment: Quench and temper
Operation Sequence
| Op | Description | Equipment | Control point | Initial |
|---|---|---|---|---|
| 10 | Saw billet to length, check weight | Band saw | Weight tolerance | |
| 20 | Induction heat billet | Heater | Exit temperature | |
| 30 | Forge and flash | 1600 tonne mechanical press | Fill, no laps | |
| 40 | Trim flash and punch | Trim press | Flash land | |
| 50 | Heat treat | Furnace | Cycle record | |
| 60 | Shot blast and inspect | Blast cabinet | Visual, MPI |
Special Instructions
Lubricate die every cycle. Record die temperature at start of lot. First piece approval before release.
Approvals
This is a starting format. Align operation numbers with your ERP routing so the process sheet and the routing do not disagree.
Compare process sheets with ERP routings
Optional: a short review of how routings and controlled documents could be cross checked.
Optional. The tool and every export work without this. No spam.
How to use this template
Fill the setup fields at the top, then review the operation table and add or remove rows to match your route. Export to Word or PDF and attach it to the traveler. Keep the operation numbers in step with your ERP routing, so a change to the routing triggers a revision of the sheet. Keep the control points short and measurable so operators can check them at the machine.
What belongs on the sheet
Material and specification, billet size and weight, heating method and temperature window, die set and press, flash and trim approach, post forge heat treatment and the final inspection. Temperature windows matter most. Forging too cold risks cracks and incomplete fill, too hot risks excessive scale, grain growth and burning in some alloys. Record the actual window used on the first article.
Linking to routing and quality
In SAP, Infor, Epicor and similar systems, the same operation sequence lives in the routing or work center structure. A process sheet that drifts from the routing causes wrong costing and missed inspections. Review both together at each engineering change, and add the inspection plan characteristics, such as hardness, grain flow or magnetic particle checks, as separate lines.
Common mistakes
Frequent problems are copying a sheet from a similar part and leaving old die numbers, leaving billet weight tolerances undefined, and omitting the die lubrication and warm up rules that decide first article quality. Treat the sheet as a controlled document with a revision and an approval, not as a loose note.
Frequently Asked Questions
Is this suitable for open die forging?
Yes. Select open die in the process field and replace the operation rows with your heat, upset, draw and reheat sequence. The header, approvals and special instruction blocks still apply.
Should die life be tracked on the process sheet?
Reference the die set number here and track hits and wear in a separate die log. That keeps the process sheet stable while the wear data changes every shift.
Can I export to Excel?
Yes, the tool exports PDF, Word, Excel and CSV. Excel is handy if you want to paste the operation table into a routing upload file.
Who approves a forging process sheet?
Typically the process engineer prepares it and production and quality approve it. Customer controlled parts may also need customer approval of any change.
If you keep routings and process data in an ERP, Netray can help compare routing steps with controlled documents on your own infrastructure.
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