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The Role of Flash in Forging

The amount of Flash during forging

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JAFFER
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828 views

The Role of Flash in Forging

The amount of Flash during forging

Uploaded by

JAFFER
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
Available Formats
Download as PDF or read online on Scribd
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Design for Hot Forging 595 Blocker forgings require more subsequent machining to reach the final part shape than conventional forgings. Precision forgings are parts formed with thinner sections and closer tolerances than equivalent conventional forgings, ie., nearer to net shape. Such forgings require careful processing, and peak loads during the final forming stages are 2.5 to 3 times higher than those experienced for equivalent conventional forging (see Sec. 14.7). Thus larger equipment and more precise die-to-die positioning is required. Although the term precision forging implies closer precision than is normally obtained for any material, in practice precision forgings are more often produced in light alloys (aluminum alloys, magnesium alloys, etc.) than in other materials, 14.3. THE ROLE OF FLASH IN FORGING The flash produced during closed-die forging is scrap material and may in many cases have a volume that is more than 50% of the final part volume. The amount of flash produced increases with the complexity of the part, However, the production of flash is a necessary part of the process, and its control is essential to ensure good die filling, particularly for tall, thin shape features. Figure 1 shows the deformation that takes place during the forging of a relatively simple axisymmetrical forging. At the start of deformation the initial stock material Upsetting Cavity filed completely Filling Forging energy Forging loag Flash begins to form Dies contact Forging (0) workpiece completed (@) FIG. 14.2 (a) Forging of a simple axisymmetric part. (b) Load variation during the stroke for forging the part. (From Ref. 1.) 596 Chapter 14 (billet) is being upset, and the corresponding forging load is relatively low. Upsetting-type deformation is the most natural form of deformation between dies and the material flows sideways, to form a flattened shape. However, if material is, to be forced to move into the extremities of the die cavity, this sideways material flow must be restricted. This is the role of flash formation, A narrow flash land around the split line of the dies restricts the sideways flow of the material, In the final stages of die closure material is extruded through the flash land into the flash gutter around the forging cavity. As the deformation proceeds, the narrowing gap between the flash lands begins to restrict the sideways flow of material, through increased friction and other forces. The forging load begins to rise and the pressure inside the die increases. This increased pressure causes material to flow backwards in the direction of die closure and into the extremities of the die cavity. At the final stage of die closure, the forging load reaches its peak and this corresponds to complete die filling. At this point the last part of the flash is being squeezed through the flash land. The selection of appropriate values for the flash land geometry (gap and width) is critical to good die filling during forging, without excessive forging loads and cavity pressures. 14.3.1 Determination of the Flash Land Geometry Figure 14.3 shows a typical arrangement for the flash land and the flash gutter on a forging. The gutter must be large enough to accommodate the flash produced. The choice of the appropriate width and thickness of the flash land is an important part of the forging process design. If the geometry is wrong, the dies may not fill completely or the forging loads may become excessive. In addition, the projected area of the flash in the flash lands is usually included in the total projected area of the part for estimation of the forging loads required and FIG. 14.3 Flash land and flash gutter configuration.

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