ASSAB-Forging EN
ASSAB-Forging EN
FORGING
APPLICATIONS
HOT FORGING
OF METALS
In hot forging a heated up billet is pressed between
a die set to a nearly finished product. Large numbers
of solid metal parts are produced in aluminium alloys,
copper alloys, steel or super-alloys where irregular
shapes need to be combined with good mechanical
properties.The main methods of drop forging are
hammer forging and press forging.
HAMMER FORGING
Hammer forging is characterised by a very short
contact time and very rapid rate of increase of force
with time (impact loading). The cumulative contact
time for the bottom die can be fairly long if one
includes the time between blows. However, since a
lubricant with “blow-out” effect is normally used with
hammers, effective contact between the part and the
die only occurs during the actual forging blow.
These features imply that impact toughness and
ductility are important properties for die steel to
be used in hammer dies. This does not mean to say
that wear resistance is not important, particularly in
smaller dies, which in fact normally fail as a result of
wear. In hammer forging, there is a lot to be said for
using inserts of a more wear-resistant die steel which
are shrink fitted into a tough holder material.
CONTENTS
HOT FORGING 2
WARM FORGING 5
PROGRESSIVE FORGING 6
EFFECT OF FORGING PARAMETERS
8
ON DIE LIFE
DIE DESIGN AND DIE LIFE 9
“ASSAB” and the logo are trademark registered. The information contained herein is based on our present state of knowledge and is intended to provide
general notes on our products and their uses. Therefore, it should not be construed as a warranty of specific properties of the products described or a
warranty for fitness for a particular purpose. Each user of ASSAB products is responsible for making its own determination as to the suitability of ASSAB
products and services.
Edition 20210505
PLASTIC DEFORMATION
This occurs when the die is locally subjected to
stresses in excess of the yield strength of the die
steel. Plastic deformation is quite common at small
convex radii, or when long thin tooling components
e.g. punches, are subjected to high bending stresses.
The following can be the cause of plastic deformation
in forging dies:
z too low billet temperature (high flow stress of
work material)
z inadequate hot strength of die steel
z die temperature too high
z die material too soft
WARM FORGING
Warm forging is a precision forging operation carried
out at a temperature range between 550–950°C It is
useful for forging of details with intricate shapes, with
desirable grain flow, good surface finish and tighter
dimensional tolerances than if hot forged.
The weight of the forged piece is between 0.1–50
kg and the production rate about 10–40 pieces per
minute. The contact time is about 200 ms and the
mechanical loads at 600°C are 3 to 5 times higher
than in hot forging.
Automatic multistation presses with integrated
cooling/lubricating systems are often used.
FORGEABILITY
Stainless
Moderate steels
Ni- and
Al-Mg-alloys Co- alloys
Ti-alloys
Low
TYPE OF LUBRICANT
Oil-based lubricants can give rise to excessive wear/
erosion due to the explosion-like combustion of
the oil between billet and cavity. On the other hand,
water base lubricants cool the die surface to a
greater extent which increases the risk of thermal
fatigue cracking. Grinding of dove-tail radii.
Assuming that the forging equipment is in good It is very important that the die is properly supported
condition (properly adjusted and without excessive underneath by a perfectly flat backing surface with
play in the ram guide system), then adherence to the sufficient hardness. Concave depressions in the
following “die design” principles will reduce the risk support surface immediately under the die cavity are
for catastrophic die failure: particularly deleterious because they exaggerate the
tensile stresses at radii.
z proper die support
z dovetails, if used, should be properly Proper backing is especially important in hammer
dimensioned, forging because there is usually no side support in
z have sufficiently large radii and beproperly this case. When dies of greatly different dimensions
finished (grinding marks should betangential and are used on the same press or hammer, it is essential
not axial), see figure below. to remove any cavities in the backing block or plate
z sufficient wall thickness, and sufficient material when switching from a small to a large die.
below the cavity and between individual cavities For press forging, side support of the die is desirable
z adequate radii and fillets in the cavity but this is not always possible. Shrink fitting of inserts
z proper dimensioning of flash land and gutter into a massive holder provides the best security
z proper design of parting plane and, if used, die against cracking in press dies.
locks
temperature. mm mm
6 12
DIE MATERIAL AND WALL 10 20
THICKNESS
16 32
A number of more or less empirical methods or
25 40
dimensioning of forging dies are available, which
range in complexity from simple “rule of thumb” to 40 56
fairly advanced nomograms with a theoretical base. 63 80
However, there is no doubt that the stresses imparted 100 110
to the die by a given forging machine increase 120 130
profoundly as the die dimensions are decreased.
160 160
TEMPER RESISTANCE
The better the steel retains its hardness as the
temperature or the time increases, the better its
temper resistance.
Temper resistance can be assessed from the
tempering curve for a hardened tool steel. In this,
the hardness at room temperature is plotted against
tempering temperature for given tempering time.
Another method of presenting temper resistance
data is to plot room temperature hardness against
time at a given tempering temperature.
FATIGUE RESISTANCE
ASSAB tool steel for forging dies are produced to
the highest possible quality standards, especially
with regard to freedom from nonmetallic inclusions.
This imparts a degree of fatigue resistance which is
adequate for even the most demanding applications
where forging dies are subjected to cyclic loading
with high maximum loads. batch to batch.
Machinability, weldability and, when applicable, For forging dies, where toughness is of the utmost
response to heat treatment and surface treatment importance, it is essential that the coolingrate
are important parameters influencing the relative during hardening is sufficiently rapid that undesirable
ease of manufacture and maintenance of forging dies. microconstituents such as pronounced grain-
boundary carbide precipitation, pearlite and coarse
MACHINABILITY upper bainite can be avoided. Furthermore, the
Machinability is a vital consideration when forging austenitizing conditions should be such that excessive
dies are machined from prehardened die blocks. grain growth can not occur, since this is detrimental
as regards to toughness. Because forging dies are
The tool steel for forging applications from ASSAB
sometimes EDM’d extensively after heat treatment,
are characterised by freedom from oxidic inclusions
there is generally no problem to cope with the
and a uniform microstructure.
greater dimensional change and distortion which
These features, in combination with the low hardness results when the rate of cooling during hardening is
in the annealed condition usually 170– 200 HB, are to rapid. Remember, however, that EDM’d dies should
ensure excellent machinability. always be given an additional temper at about 25°C
below the previous tempering temperature. Detailed
Even if these grades are supplied prehardened, the
heat treatment recommendations for the various
extreme cleanliness and microstructural homogeneity
grades, in ASSAB’s tool steel programme for forging
ensure that machining can normally be carried out
dies, are given in the product brochure.
without difficulty.
For all products, advanced process control guarantees WELD REPAIR OF FORGING DIES
that the variations in machining characteristics are
Cracked or worn forging dies are often refurbished
minimal from batch to batch.
via welding. This is especially true in the case of
large dies where the tool steel itself represents a
HEAT TREATMENT
considerable portion of the total die cost.
If forging dies are manufactured from die steel in the
annealed condition, then the tool must subsequently
be heat treated in order that the steel develops its
SURFACE TREATMENT
optimum combination of hardness, toughness, heat The cavity in forging dies is quite often surface
resistance and wear resistance. treated in order to enhance wear resistance.
Notch toughness of ASSAB 8407 Supreme, 44–46 HRC, as a function of quench rate.
200oC
20oC
ASSAB 8407 2M ASSAB 8407 2M is a H13 grade with good high-temperature strength and hot-wear
resistance. It has a comprehensive dimension programme of round sizes. 8407 2M is
processed in a special way (microdised) giving a high purity and a good structure for
better tool performance.
ASSAB 8407 SUPREME ASSAB 8407 Supreme is an electroslag remelted steel, which attains high purity and
a very fine structure. It is a premium H13 grade with significantly improved isotropic
properties compared to conventionally produced H13 grades. This improvement,
coupled with a high level of cleanliness and homogeneous structure, makes 8407
Supreme particularly suitable for demanding applications (e.g., tooling subjected to
high stresses). It meets the requirements of NADCA #207–2008..
QRO 90 SUPREME QRO 90 Supreme has a good combination of high-temperature strength, temper
resistance and thermal conductivity. QRO 90 Supreme has given many outstanding
results for press forging of steel and brass, particularly in small- and medium-sized
inserts or dies. It is also eminently suitable for progressive forging, upset forging,
extrusion forging, powder forging and all processes where heavy water cooling is used.
Formvar Formvar is a solid upgrade choice from H11/H13 forging dies. With good tempering
resistance and hot yield strength.
ASSAB PM 23 SUPERCLEAN Powder metallurgy high-speed steels characterised by high compressive strength,
ASSAB PM 30 SUPERCLEAN high hardness after hardening, good toughness, very good wear resistance, very good
dimensional stability during heat treatment, and very good tempering resistance.
These grades are used for forging applications where very good wear resistance is
needed.
CHEMICAL COMPOSITION
ASSAB grade AISI (WNr.) Analysis % Supplied
hardness
C Si Mn Cr Mo V Others Brinell
ASSAB 8407 2M H13 (1.2344) 0.39 1.0 0.4 5.3 1.3 0.9 - ~180
ASSAB 8407 SUPREME H13 (1.2344) 0.39 1.0 0.4 5.2 1.4 0.9 - ~180
QRO 90 SUPREME - 0.38 0.3 0.8 2.6 2.3 0.9 Microalloyed ~180