Forging

Forging
It is the process by which metal is heated and
is shaped by plastic deformation
By applying compressive force (impact or
gradual pressure).
It is a process in which the work is
compressed between two dies using either
impact or gradual pressure to form the part.
Oldest of metal forming operations and now
used to make high strength components.

Forging

Forging

Forging
Equipment:
A forging machine that applies an impact load is
called a forging hammer.
A forging machine that applies gradual pressure is
called forging press
Forging hammer
Gravity drop hammer achieve their energy by falling
the weight of the ram
Force is determined by the height of the drop and the
weight of the ram and produces impact energy.
Power drop hammer accelerate the ram by
pressurized air or steam.

Press Forging
Press forging use a slow squeezing action of a press, to
transfer a great amount of compressive force to the
workpiece.
Unlike an open-die forging where multiple blows transfer
the compressive energy to the outside of the product,
Press forging transfers the force uniformly to the bulk of
the material.
This results in uniform material properties and is
necessary for large weight forgings.
Parts made with this process can be quite large as much
as 125 kg (260 lb) and 3m (10 feet) long.

OPEN DIE FORGING

Forging
Open die forgings or hand forgings are made with
repeated blows in an open die, where the operator
manipulates the workpiece in the die.
The finished product is a rough approximation of the die.
Open die forging involves the shaping of heated metal
parts between a top die attached to a ram and a bottom die
attached to a press bed.
Metal parts are worked above their recrystallization
temperatures-ranging from 1900F to 2400F for steel
And gradually shaped into the desired configuration
through the skillful hammering or pressing of the work
piece.

Forging
The open die forging process is often associated with
larger, simpler-shaped parts such as bars, blanks,
rings, hollows or spindles,
High-strength, long-life parts optimized in terms of
both mechanical properties and structural integrity
Produced in sizes that range from a few pounds to
hundreds of tons in weight.
In addition, advanced forge shops now offer shapes
that were never before thought capable of being
produced by the open die forging process.

Steps to produce a typical spindle-shaped

Flow of Materials
Complex shapes in impression die
forging
Calculation of forces are difficult?
Depend on the position, each
element is subjected to different
strains and strain rate

Forging
Forging refines the grain structure and improves
physical properties of the metal.
With proper design, the grain flow can be oriented in
the direction of principal stresses encountered in
actual use.
Physical properties (such as strength, ductility and
toughness) are much better in a forging than in the
base metal.

Forging
A Forged metal can result in the following :
Increase length, decrease cross-section, called drawing out the
metal.
Decrease length, increase cross-section
called upsetting the metal or upset forging.

(diameter),

Change length, change cross-section, by squeezing in closed

impression dies.

Forging
Working Temperatures:
Hot working of metals (above recrystallization
temperature)
Cold working of metals (below recrystallization
temperature)

Forging
Depending upon the types of the dies:
Open die forging
Impression die forging (closed die forging)
Flash less forging

Forging
Open die forging/Hand forging
Upset forging
Fullering
Edging
Cogging
Impression die forging/Precision forging
Net shape/Near net shape forging
Flashless forging
Coining
Press forging
Ring forging
Swaging

Forging
Upset forging:
Reduces the height of the work and increases its diameter.
Upset forging increases cross-section by compressing the
length, this is used in making heads on bolts and fasteners,
valves and other similar parts.

 Edging is the process of concentrating material

using a concave shaped open die.
The process is called edging because it is usually
carried out on the ends of the workpiece.
Similar to fullering, except that the dies have concave(hollow)
surfaces.
Fullering:
To reduce the cross section and redistribute the metal in a work
part in preparation for subsequent shape forging.
It is accomplished by dies with convex (rounded) surfaces.

These processes prepare the workpieces

for further forging processes.

Cogging
Successive deformation of a bar along its length
using an open-die drop forge
Operation consists of a sequence of forging compressions along
the length of a work piece to reduce cross section and increase
length.
Used in steel industry to produce blooms and slabs from cast
ingots.
It is accomplished using open dies with flat or slightly contoured
surfaces.
Term incremental forging is sometimes used for this process.
It is commonly used to work a piece of raw material
to the proper thickness.
Once the proper thickness is achieved the proper
width is achieved via edging.

Cogging

Swaging
The process can alter the diameter of rods,
hoses(pipe) and/or tubes.
A tube or rod is forced inside a die and the diameter is reduced
as the cylindrical object is fed
Examples of swaging include pipefitting, hose
fitting and decorative metal work.

Impression Die Forgings / Precision Forgings

Impression die forgings and precision forgings are
further refinements of the blocker forgings.
The finished part more closely resembles the die
impression.
Impression-die forging is also called closed-die
forging.
In impression-die work metal is placed in a die
resembling a mold, which is attached to the anvil.
Usually the hammer die is shaped as well.
The hammer is then dropped on the workpiece,
causing the metal to flow and fill the die cavities.

Impression Die Forgings

The hammer is generally in contact with the workpiece on the
scale of milliseconds.
Depending on the size and complexity of the part the hammer
may be dropped multiple times in quick succession.
Excess metal is squeezed out of the die cavities, forming what
is referred to as flash.
The flash cools more rapidly than the rest of the material;
This cool metal is stronger than the metal in the die so it helps
prevent more flash from forming.
This also forces the metal to completely fill the die cavity.
After forging the flash is removed.

Forging
Flash, also known as flashing, is excess material
attached to a molded, forged, or cast product,
which must usually be removed.
This is typically caused by leakage of the
material between the two surfaces of a mold
Beginning along the parting line
It results in wastage of material in the form of
material flash and subsequent machining
operations.

Net Shape / Near-Net Shape Forging

Net-shape and near-net-shape processes minimize the
waste by making precision dies, producing parts with
very little draft angle (taper)less than 1.
These types of processes often eliminate or reduce
machining.
The processes are quite expensive in terms of tooling
and the capital expenditure required.

Flashless Forging
Also known as precision forging/closed die forging.
No flash is formed (workpiece is completely
contained within the die cavity during compression)
Work volume must equal the space in the die cavity
within a very close tolerance.
If starting block is too large, excessive pressure may
cause damage to the die or press.
If the block is too small, the cavity will not be filled.

Coining
Special application of closed-die forging
Fine details in the die are impressed into the top and
bottom surfaces of the workpart.
There is a little flow of metals in coining, yet the pressures
required to reproduce the surface details in the die cavity
are high.
Common applications is, of course, in the minting of
coins, medals etc.

Forging Advantages
Forging stock is also typically pre-worked to refine
the dendritic structure of the ingot and remove
defects or porosity
By mechanically deforming the heated metal
under tightly controlled conditions, forging
produces predictable and uniform grain size and
flow characteristics.
These
qualities
translate
into
superior
metallurgical and mechanical qualities, and
deliver increased directional strength in the final
part.

Forging

Structural Strength
Forging also provides a degree of structural integrity
that is unmatched by other metalworking processes.
Forging eliminates internal voids and gas pockets that
can weaken metal parts.
By dispersing segregation of alloys, forging provides
superior chemical uniformity.
Predictable structural integrity reduces part inspection
requirements,
Simplifies heat treating and machining, and ensures
optimum part performance under field-load conditions.

Advantages of Forging
1. Forged parts possess high ductility and
offers great resistance to impact and fatigue
loads.
2. Forging refines the grain structure of the
metal.
3. It results in considerable saving in time,
labor and material as compared to the
production of similar item by cutting from a
solid stock and then shaping it.
4.Because of intense working, flaws are rarely
found, so have good reliability.

Disadvantages of Forging
1. Rapid oxidation in forging of metal surface at
high temperature results in scaling which wears
the dies.
2. The close tolerances in forging operations are
difficult to maintain.
3. Forging is limited to simple shapes
4. The initial cost of forging dies and the cost of
their maintenance is high.
5. The metals gets cracked or distorted if worked
below a specified temperature limit.
6. The maintenance cost of forging dies is also
very high.

DEFECTS IN FORGED PARTS

1. Mismatched forging
Reasons
Due to non alignment of proper die halves.
2. Brunt and overheated metal
Reasons
This is caused by improper heating the metal at high
temperature or for a long time.
3. Scale pits
Reason
These are formed by squeezing of scale into the metal
surface during forging.
4. Oversize components
Reasons
Due to worn out dies, incorrect dies, misalignment of die
halves.

Applications of Forging
The low and medium carbon steels are readily
hot forged without difficulty,
The high-carbon and alloy steels are more difficult
to forge and require greater care.
Stainless steels, nickel based super-alloys, and
titanium are forged especially for aerospace uses.
Producing of crank shaft of alloy steel is a good
example which is produced by forging.
Forging processes are also extensively used in
the manufacturing of
the parts of tractors,
shipbuilding,
cycle
industries,
agricultural
machinery etc.

Flow of Materials

Cogging
A method of metalworking used to change the grain of a
piece of metal.
It is a hot forging technique involving two anvils with
shaped surfaces.
This kind of shaped anvil is called a "die."
The term "cogging" may come from the fact that the metal
is meant to be pressed into the shape of the die in the same
way two cogs(moving parts) will fit into each other, though
the shape of the die is not always rectangular.
Cogging is often an intermediate stage in the metalworking
process.
It is used to change the internal structure of ingots.
After cogging, the finished ingots, now called billets, are
refined pieces of metal which can then be forged into more
complex components.

Ring Forging
In roll forging, a bar stock, round or flat is placed between die
rollers which reduces the cross-section and increases the length
to form parts such as axles, leaf springs etc.
This is essentially a form of draw forging.
The process starts with a circular preform of metal that has
been previously upset and pierced (using the open die forging
process) to form a hollow "donut".
This donut is heated above the recrystallization temperature
and placed over the idler or mandrel roll.
This idler roll then moves under pressure toward a drive roll
that continuously rotates to reduce the wall thickness, thereby
increasing the diameters (I.D. and O.D.) of the resulting ring.

Forging
Seamless rings can be produced in configurations
ranging from flat,
washer-like parts
To tall, cylindrical shapes,
with heights ranging from less than an inch to more
than 9 feet.

Forging

Producing a ring "preform" by the

open die forging process:
Starting stock cut to size by weight is
first rounded, then upset to achieve structural
integrity and directional grain flow.

Work piece is punched, then pierced

to achieve starting "donut" shape needed
for ring rolling process.

Completed preform ready for

placement on ring mill for rolling.

Forging

Ring rolling process begins with

the idler roll applying pressure to
the preform against the drive roll.

Ring diameters are increased as the

continuous pressure reduces the wall thickness.
The axial rolls control the height of the
ring as it is being rolled.

The process continues until the

desired size is achieved.