Hot Forming

Kalpakjian
Hot Working:
Forging

[Link]

Open Die Forging

[Link], WIT
Paul Berenson, [Link]
Forging: Heat Loss
Metal near die surfaces are coolest, flow less

[Link]
 Temperature in Metal Forming

• For any metal, K and n in the flow curve

depend on temperature
• Both strength and strain hardening are
reduced at higher temperatures
• In addition, ductility is increased at higher
temperatures
• Tm is melting temperature +273
 Comparison

Cold Working Hot Working

Carried below recrystallization temp. Carried above recrystallization temp.
Hardening is not eliminated, rather Strain hardening is completely
accompanied by strain hardening eliminated
Elongation, area reduction, ductility Ductility, elongation, area reduction
and impact strength are reduced and impact strength are increased
Crystallization does not occur Crystallization occurs again
Uniformity of material is lost and Grain refinement occurs
properties are greatly affected
Chances of crack propagation is Cracks and defects like blow holes,
more cavities are welded
Increases ultimate tensile strength, Does not affect ultimate tensile
yield point, hardness, fatigue strength, yield point, hardness,
strength fatigue strength

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Resistance to corrosion decreases Resistance to corrosion is not
due to presence of residual stresses affected
Internal and residual stresses are Internal and residual stresses are not
produced produced
Load and energy requirements are Load and energy requirements are
high low
Less tool wear High tool wear
Less costly High cost operation
No oxidation of metal occurs High scaling and oxidation occurs
No metal loss High metal loss
Surface decarbonization of steel Surface decarbonization of steel
does not occur occurs
Good surface finish Surface finish is not good
High dimensional accurcy low dimensional accurcy
Easy to control dimensions within Difficult to control dimensions within
tolerance limits tolerance limits
Material handling is easy Material handling is difficult
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 FORGING

• Forging is term applied to a family of processes where

deformation is induced by localized compressive forces.

• The equipment can be manual or power hammers, presses, or

special forging machines.

• The hot forging done above the recrystaIlization temperature.

• The cold forging done below the recrystaIlization temperature.

 FORGING
• The forging material may be subjected to:

 1-Drawn out to increase its length and

decrease its cross section,

– 2-Upset to decrease the length and increase

the cross section,

– 3-Squeezed in closed impression dies to

produce multidirectional flow.
 Different types of Forging processes

• Open Die Forgings or Hand forgings.

•Impression Die Forgings or Precision Forgings or

closed die forging.

• Upset Forgings
1- Open Die Forgings or Hand forgings.

In this process the forgings are made with the help of

repeated blows in an open die. Here the operator
manipulates the work piece in the die during the ‘blow’
process, similar to the traditional manufacturing process
used by a blacksmith.
 Open Die Forgings or Hand forgings

• Open-die forging is the same type of forging done by

blacksmith. Metal is first heated to proper temperature by gas,
oil, or electric furnaces.

• Impact delivered by some type of hammer like pneumatic

hammer or board hammer.
 Open die forging

Blacksmiths use this process to reduce the thickness of bars by hammering the part on an
anvil. Reduction in thickness is accompanied by barreling, as in Fig. 14.3c. (b) Reducing the
diameter of a bar by open-die forging; note the movements of the dies and the workpiece. (c)
The thickness of a ring being reduced by open-die forging.
Stages in Open-Die Forging

(a) forge hot billet to max diameter

(b) “fuller: tool to mark step-locations

(c) forge right side

(d) reverse part, forge left side

(e) finish (dimension control)

[source:[Link]]
 Open-Die Drop-Hammer Forging
• Steam or air hammers(pneumatic hammers) use pressure to :

give higher striking velocities,

– more control of striking force,
– easier automation,
– the ability to shape pieces up to several tons.
pneumatic hammer
 Open-Die Drop-Hammer Forging

• Open-die forging is usually employed to pre-shape metal for

further manufacturing operations for example consider such
massive parts turbine rotors and generator shafts which may
be 70 ft in length and up to 3 ft in diameter.

• Open-die forging is used to minimize the amount of subsequent

machining.
• Open die forging is considered as a primary forging process.
 2-Impression-Die Drop-Hammer Forging
  Impression Die Forgings or Precision Forgings

These forgings are the refined form of blocker forgings. The

finished metal part much more identical to the die impression.

• Impression-die or closed-die forging overcomes these

difficulties of obtaining the final shape by using shaped dies to
control the flow of metal.

• Consist of set of dies, one half of which attaches to hammer

and other half to anvil.

• Impression die may be flash and flash less

 Impression-Die Drop-Hammer Forging
• Heated metal is positioned in lower cavity and struck one or
more blows by upper die.
• Hammering causes the metal to flow to completely fill die
cavity.
• Excess metal is squeezed out around the periphery of the
cavity to form a flash.
• When final forging is completed, flash is trimmed off by
trimming die.
Stages in Impression-die (Closed-Die) Forging
Stages in Impression-die (Closed-Die) Forging( flash)

[source:Kalpakjian & Schmid]

Stages in Impression-die (Closed-Die)
Forging(flash)
 Impression-Die Forging( flash shape)

(a) through (c) Stages in impression-die forging of a solid round billet. Note the formation
of flash, which is excess metal that is subsequently trimmed off (d) Standard terminology
for various features of a forging die.
Flash less forging
 Impression-Die Drop-Hammer Forging

• Final shape and size are set by additional forging in the final or
finisher impression
• The shape of the various cavities forces the metal to flow in the
desired direction.
• After forging, the flash is trimmed

• The part is quenched to room temperature.

 Impression-Die Drop-Hammer Forging

Advantages
1- complicated shapes
2- accurate dimensions.
3- better surface properties.
4- can be used in mass production scale.
5- mechanical properties is achieved by thermal
treatment.
6- reduce scraps by using flash.
Trimming Flash After Forging

Trimming flash from a forged part. Note that the thin

material at the center is removed by punching.
 Press Forging
• Hydraulic presses with capacities up to 50,000 tons (445 MN)
are used.

• Press forgings have higher dimensional accuracy and can often

be completed in a single closing of dies and the process can be
readily automated.
• 10000T10010000 ton
 Upset Forging
Upsetting or Upset Forging is the simplest case of open-die
forging involving compression of a workpiece between two
flat dies. Upset forging reduces the height of the workpiece
but increases its cross-sectional area. We will consider
upsetting of a round billet.
Under ideal conditions where there is no friction between the
work piece and the dies, the billet deforms homogeneously
(the cylindrical shape of the billet remains cylindrical
throughout the process). But in practical conditions the billet
tends to barrel since there is some friction.

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 Homogeneous upsetting of a cylindrical billet (without friction)

Homogeneous

Practical upsetting
Practical upsetting of a cylindrical
of a cylindrical billet &(with
billet (with friction friction &
barreling)
barreling)

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 Terminology
In homogeneous upsetting / no friction:
ho
True Strain,   ln (1)
h
ho = starting height of workpiece (before deformation)
h = instantaneous height of the work piece (at an
intermediate press stroke)
F
True Stress   (2)
A

F = instantaneous upsetting force

A = instantaneous cross sectional area of the workpiece

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 Terminology
In homogeneous upsetting:

Upsetting Force F  Y f A (3)

Y f  flow stress  K n
(4)

K = strength coefficient, n = strain hardening coefficient

F increases with deformation (press stroke) since Yf and

A both increase with deformation and strain (Eqs. (1), (3)
& (4))

32
 Terminology
Practical Upsetting of a cylindrical workpiece (with friction &
barreling):
F  K f Yf A (5)

0.4D
Forging Shape Factor K f  1 (6)
h

Where  = coefficient of friction (0.05 – 0.3)

D = instantaneous workpiece diameter, mm (in),
h = instantaneous workpiece height, mm (in)

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Specimen before and after the compression:

ho

h1

Do
D1 (avg)

Do2 h0
V  billet volume 
4
D1 (average) can be calculated from volume constancy, i.e.,
V .4
D1 
h1 34
Specimen before and after the compression:

Original Specimen

Barreled Specimen
after compression

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Comparison of cold and hot forging:

Original steel specimen Steel specimen Steel specimen

after cold forging after hot forging
(5 steps/hits)

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 Swaging
• Swaging generally involves the hammering of a rod or tube to
reduce its diameter where the die itself acts as the hammer
• Term swaging is also applied to processes where material is
forced into a confining die to reduce its diameter.
 Swaging

Schematic illustration of the rotary-swaging process. (b) Forming internal profiles on a

tubular workpiece by swaging. (c) A die-closing swaging machine showing forming of a
stepped shaft. (d) Typical parts made by swaging. Source: Courtesy of J. Richard
Industries.
 Coining
• Closed-die forging process

• Closed-die forging process

• Used for minting coins, medallions, & jewelry

• Lubricants can not be used in coining
• Can be used to improve surface finish