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Forging: - Forging Is A Bulk Deformation Process in Which The Work Is Compressed Between Two Dies

Forging is a bulk deformation process that compresses workpieces between two dies. Most forging is done hot. There are three types of forging dies: open-die, impression-die, and flashless. Impression-die forging provides precision with close tolerances but the dies are expensive. It involves multiple stages: blanking, edging, blocking, and finishing. Flashless forging requires the workpiece volume to exactly match the die cavity. Upsetting is used to form heads on parts like bolts and involves heading and then thread rolling. Die material properties like strength, hardness, and wear resistance are important. Forging analysis can determine forces at different stages of deformation based on material properties and die geometry

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26 views20 pages

Forging: - Forging Is A Bulk Deformation Process in Which The Work Is Compressed Between Two Dies

Forging is a bulk deformation process that compresses workpieces between two dies. Most forging is done hot. There are three types of forging dies: open-die, impression-die, and flashless. Impression-die forging provides precision with close tolerances but the dies are expensive. It involves multiple stages: blanking, edging, blocking, and finishing. Flashless forging requires the workpiece volume to exactly match the die cavity. Upsetting is used to form heads on parts like bolts and involves heading and then thread rolling. Die material properties like strength, hardness, and wear resistance are important. Forging analysis can determine forces at different stages of deformation based on material properties and die geometry

Uploaded by

berhane
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
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Download as PPT, PDF, TXT or read online on Scribd

Forging

• Forging is a Bulk
Deformation Process in
which the work is
compressed between two
dies.
Forging

• Most forging operations


are carried out hot,
although certain metals
may be cold-forged.

• Forging machines are


now capable of making
parts ranging in size of a
bolt to a turbine rotor.
Types of Forging Dies
• According to the degree to which the flow of the
metal is constrained by the dies there are three
types of forging:
a)ΠOpen-die forging
b) Impression-die forging
c) Flash less forging
Open-Die Forging with Friction

• Compression of work with cylindrical cross-section


between two flat dies
• Similar to compression test
• Deformation operation reduces height and increases
diameter of work
• Common names include upsetting or upset forging
Impression-die (Closed-Die) Forging
• Workpiece is deformed
between two die halves which
carry the impressions of the
desired final shape
• The workpiece is deformed
under high pressure in a
closed cavity
• Used for smaller components
• The process provides
precision forging with close
dimensional tolerance
• Closed dies are expensive
Impression-die (Closed-Die) Forging

(a) (a) (a)

(b) (b) (b)

Flash Flash Flash


(c) (c) (c)

1. (bar)
Blank1.(bar)
Blank 2.
(bar)
Edging
2. Edging
3.Blocking
1. Blank 2. Edging 3.Blocking 4.3.Blocking
4. Finishing
Finishing 4.
5. Finishing
5. Trimming
Trimming 5. Trimming

[source:Kalpakjian & Schmid]


Stages in Impression-die (Closed-Die) Forging
Flashless Forging

• Starting workpart volume must be equal to die cavity


volume within very close tolerance
• Best suited to part geometries that are simple and
symmetrical
• Often classified as a precision forging process
Upsetting/heading

• Forging process used to form heads on nails, bolts, and similar


hardware products
• More parts produced by upsetting than any other forging
operation
• Performed cold, warm, or hot on machines called headers or
formers
Upsetting/heading

• Wire or bar stock is fed into machine, end is headed,


then piece is cut
• For bolts and screws, thread rolling is then used to form
threads
Die material
• Required properties • Carbon steels
– Thermal shock • Medium alloyed tool
resistant steel
– High temperature
• High alloyed steel
strength
– High wear resistance
– High hardness
– High dimensional
stability
– Good machinablilty
Forging analysis
Forging analysis
Forging analysis
Example
• A cylindrical part is warm upset forged in an open die.
The initial diameter is 45 mm and the initial height is 40
mm. The height after forging is 25 mm. The coefficient of
friction at the die-work interface is 0.20. The work
material has a flow curve defined by a strength
coefficient of 600 MPaand a strain hardening exponent
of 0.12. Determine the force in the operation
(a) just as the yield point is reached (yield at strain =
0.002)
(b) at a height of 35 mm, and (c) at a height of 25 mm.
Solution
Solution
Solution
Solution
Thank you for your attention

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