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Theory of Metal forming forging processes last semester 2023

Forging is a metal-forming process that shapes workpieces using compressive forces through various dies and tools, producing items like bolts and gears. It can be categorized by working conditions (hot or cold) and processes (smith, drop, press, etc.), with each type having specific requirements and characteristics. Limitations such as barreling and chilling effects can affect the forging process, which utilizes different machines like presses and hammers.

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6 views

Theory of Metal forming forging processes last semester 2023

Forging is a metal-forming process that shapes workpieces using compressive forces through various dies and tools, producing items like bolts and gears. It can be categorized by working conditions (hot or cold) and processes (smith, drop, press, etc.), with each type having specific requirements and characteristics. Limitations such as barreling and chilling effects can affect the forging process, which utilizes different machines like presses and hammers.

Uploaded by

amiressam177885
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© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
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Forging

• Forging: a Process in which the work-piece is


shaped by compressive forces applied through
various dies and tools.
• Typical forged products: bolts, rivets, connecting
rods, shafts for turbines, gears, hand tools, etc...
• Forging

Metal-forming process in which the workpiece is


shaped by compressive forces applied through
various dies and tools.
Forging

• Forgeability
– Capability of a material to undergo deformation
without cracking.
– Metals which have low ductility have reduced
forgeability.

– The metals having high ductility at cold working


temperature possesses good forgeability.
• Forging is a discrete (individual) parts process
• Forging is a near net shape process
• TYPES OF FORGING
• According to working condition :
• 1. Hot forging
• 2. Cold forging
• According to the working process:
• 1. Smith forging
• 2. Drop forging
• 3. Press forging
• 4. Impression Die Forging
• 5. Rolled Forging
• Cold Forging
– Requires greater forces and workpiece materials must
have sufficient ductility at room temperature; good
surface finish and dimensional accuracy.

• Hot Forging
– Requires smaller forces, not as good finish or dimensional
accuracy; usually require additional machining.
PRESS FORGING
• Press forging is a method of forging that involves
the slow and continuous application of pressure
on the workpiece. Press forging can be carried
out either hot or cold.
DROP FORGING

• Drop forging is a forging process where a hammer


is raised and then "dropped" onto the workpiece to
deform it according to the shape of the die.
• There are two types of drop forging:
• open-die drop forging and closed-die drop forging.
Open-Die Forging
• (upsetting or flat-die forging)

• Simplest forging process.

• Solid workpiece is set between two flat dies and reduced (height)
through compression.

• Barreling (outward bowing of material) minimized with the use of


lubricants.
Open die forging -cogging
• Drawing out

• Operation where the thickness of a bar is reduced by successive


forging steps at certain intervals.

• Typical for parts such as I-beams which must be pre-shaped before


rolling
Open die forging

- (a) Ideal deformation of a solid cylindrical specimen compressed


between flat frictionless dies, an operation known as upsetting.
- (b) Deformation in upsetting with friction at the die-workpiece
interfaces. Note barrelling of the billet caused by friction.
Impression and Closed-Die Forging
Impression and Closed-Die Forging
• In impression-die forging, the work-piece acquires
the shape of the die cavities while being forged
between two shaped dies
The thin flash cools rapidly, and because of its
frictional resistance, it subjects the material in the
die cavity to high pressures, thereby encouraging the
filling of the die cavity.
• In true closed-die or flash-less forging ,flash does
not form and the work-piece completely fills the
die cavity. Consequently, the forging pressure is
very high
• If the Workpiece volume > cavity volume
filling and flash will occur.
• If the Workpiece volume < cavity volume
incomplete shape will occur.
• If the Workpiece volume = cavity volume
filling (precision forging process) will occur.
Limitation of the forging process
• Barreling effect , Barreling effect is mainly caused due to
friction between the surface work piece and the platens of the
machine or die set . Applying effective lubricant can minimize
barreling.
• Buckling effect , Buckling effect is caused due
to large ratio of ho/Do, where ho is the initial
height of the work piece and do is the initial
diameter of the work piece This effect is
avoided by keeping the ratio ho/Do between 1
to 3.

Do

ho
• Chilling effect , Due to decrease in
temperature at the region of contact between
the hot work piece and the cold platens of the
machine or the die set, Noting that the
strength of the work piece reduces when the
temperature increases, (I.e. T1>T2>T3, σ1<
σ2< σ3, ε1>ε2>ε3)
• Where
• T: temperature
• σ: stress in N/mm2
• ε: strain in the work piece
Heating the die set in the contact area may minimize it.
• Rhombic effect
Due to the small value of ratio (to/wo) , which
will produce a dead metal zone and the
material will not be forged any more.
Forging Machines
• Presses
– hydraulic
– mechanical
– screw

• Hammers
– gravity drop
– power drop
– Counterblow (two hammers)
– high-energy-rate Machines (pneumatic)
THE FORCE FOR OPEN-DIE FORGING
For open-die forging the maximum theoretical
force

where:
b: final specimen length under the punch (diameter under
the circular punch).
t : final height of the specimen under the punch.
w: final width (w = b with circular specimen section)
Related Forging Operations
• Hubbing
– pressing a hardened punch into the surface of a block of metal to produce
a cavity (create dies for tools, tableware, etc.).

• Roll Forging
– the cross section of a bar is reduced or shaped by passing it through a pair
of rolls with shaped grooves (leaf springs, hand tools). (discrete parts)
Related Forging Operations
• Skew Rolling
– similar to roll forging
– Ball bearing production
• Orbital Forging
• upper die moves along an orbital path above the
part which is also spinning.

• Incremental Forging
– process where a blank is forged into a shape in several
small steps (the die penetrates the blank at different
depths across the surface). Similar to cogging.

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