Daadantogesi) Accubhacy

2) Lalbor ntenáive

Forming
Manufacrirg PY
Pnoces

Conventional JYon-conyendio ral

caking formi ng Wdding Machining

Definition ¢ Fonming
Metal-ommring ean be
bo defonsd asas a pnoa% in cohieh
Hhe do ki ned sì xe and chapes ae obtai nad tougk the defoumofion
of mutal plaatieally undo the action of extenaly appled foncus
Defonmadion UTS

elasie
Plaste
Plastie elasie
dajormatio defommaton agin -Frmirg

bunanally foming: iald point to po Foactune paint.

In foomig material loy is tha loast & it is conuideel that

n mat hia = yolume the þno duet
ba on
the ucngulan ban
he poodueuohich is ha fooming' pmouu has
Hhe best duality eompoud to he othes manu foching pooas.
Roason! coneantnat ed ony
Cnankaha<t:manufactunsd by 'fomningnoa% ondy
chesis
(Bady of the vehicla)
P Black&math : Aediormateia
Abplying Hammahung
Gunsnaty the mad9ial i kapt on the ANVIL'. (Base)
 Fowming
(Heaf) (oyo heat)
HOT WO RKING COLD WORKING WORKING
FORmING FORMING
(Recsnystallikation mpuatur)
IRON, ’ &6 1300e
|sTAAIN HARDENINGT
usd in the industy o manukactuig
product dualty ehosis.
depends On tha (beten quality thar het formang)
tomþenatue to whieh it (dimensional acowraey is beta than
hastad. hot forming.
 Foprrng
CDLD FORMING Hor FOR MING7
’ At rO0m tamþenatw on above
Sunfaee quodity is bater. tempnate
Dimnsional aecunacy i8 mome.
Hishan fonc.
ductile matial
+0xide Sayen fommaisn
COLD FORM NGG: ’DeE Ducilet Bril
Gunsally dona
done at 900m tompuadu on abOve o
tompanatua 1. closon toleranee can be achieed.
2. Guod sunface fizhing
3. Due to stnain and handreA
in this the pat.
4. Gonain fdous duning defonmation pnoviles the
opportunity fon desinabla dinecioro propantie.
b. Sine Rooting
cost
G.
alecrity
Machinìng uginemanda
minimiaad
Ce
muninum
nat shabe þnoduet. susulting
Disadvantogo
1. Highor fonus and þouan
2. 8tnain - handning the coonk matal imits tha amount
of fowming that ean be dona.
3 Jhe wwonkpice isnot dudile anough to ba colde clad
HOT FORMIN:
Snoles da fosmation obove ucrystalli zcfion tmp
(o.3Tno-5 T )
Adventae:
1-Aicra ficant plostie de fonmation be
qiver to tha sample
2. Significant changr G9Gef csonkpiece Bhape
 3. Lowen fovees nsdunad.
Madarioals coith pa matuna failuwe. can b hot oonad.
de to cook -handening stroin-haneing
6. At a kigher temperatua, the matri al t would ha
amount of ducality and thenafon hena is no liit on ha
amount of hot-corlirg that
that can ba dona on a matariaL. Even
bnil le. material can ba hot coonkad.
1. Sine tha shao stneses highss tamforatune ,the
uduines less Ponea toto achiave the
hot-coonking nudu
nacesoy
dfonmation.
Dadantage
1. Poon sunfoca firisk, dua to the fomation of oude
2. Shonton tool- f
A Louwh
dimensional aecuhay
4. Oxidi aed.

WARMM WORKING:
Sm this cose, forming is nformud at temparatues
aloove oom tomanature but balouo oucnustali aalio tomboatuu Fha

Advontages:
1. Enhancad þlastie de forration pooparties.
Louser foneas suduined cs compoed to co ld
Sntoieote wonk m
geme gaematy fosiblaeold comparud to
ean ba Jaduced
wging
Aunaaliatng stag
(Heat tneatmnt
pnocess)
RECRYS TALL1ZATÔN -(oelatad to hot-ogvhing
Undur the action bf haat ard onea , whan atoms uael
ahich is temed
laval, he nw
Recuystetli aaion dastooys the old stouctusu defon med
machaniea
oonking onyntals cokidk.
ohich au strain 4nes
CUe
fomad. Jhe fact stant raucliating t the point
severa defonmation .
Ruoystalliza tior dampratun
idetined as the coþr oximate miimum tamfeatuwe at
wkich complata suonyekalli aalion cfof oa cold corkad mate oes
within a
sheified tine.
TIT:- ime Janpenature ranfer Inansfer
Lead, in Blow noom Jamparatwe
Cadmium, Kine ’
L50°e
tempaatune
206' e

Fe 450°c
Ni

Ji
1200°e
Ju
 FORMING
&ize
Sckumatic rapesention o gnoin
Hot coonking complated
by wi hout-Loon kiHo4
olfecked Cooling,hot
ng wonking eomblatad
cbove reegstali zatin at eeryttolizaion
Solidiu Heating tocinonking femp

Hot Hot
esNonking Fsonking

-alita

Room
DKA)
 the temponatue at uhch he cworking is
conplated is importont Bince any
wil aid on hei tha gnain grouth, hs, ajving poon muckenic
het inin the
þooprties.
Jhe effect of tampautu of completion of Hot-oking is shousn
in this figue
Ln A it is shouwn Simple haaing, ohene tha grain stats
qnouing ter the m eho ses naoustallizotion ampenatuna.
cwifhot in e, the final
When it is eo led
&ize would be
than cwhen startad in
AfHn heotig. when the metal is awonkad SoarauAL
&ize is haducod.
Hhe gnain
made
caorking of matal gives ie
to a
his is posaible because the coorkiA
umbes nuchation sats for tha no to form , but
i8 complated much aboe ncystolli zat ion temp as
in C', h si20 stonts [Link] and may finally
OCCUns
up with gmain and is a time

and tampenatune
mot deinclole.
nacyetalli zation temp as in
is comleted at
D, hun the ssultant g9n
Stnain -Handaing
strain (ealeted ith coÓ-wsking
qain

change (ost)
 EORMINI
RAM
Uppen Die
ionkpicee
Lowr
Die

) Hanmen

3) Pre%

manufactuung f coin; pnes

be delinad as the contooll.A plastie de ponmation of
matals ct at elavatel demperature indo a fnedtaniyel
gie compnessive ernted
bma tyhe of die on b hammen
Bome
machina.

chaacteisiesi
DForging is a plastie tleu b ha applicafior
Comjmcrsive fooas cohieh si2c and ehate is ehanged
without faile.
posmamantdy
def onmain pnoas in cohich onk is
)Fonging
combnessad batoen ithen impact on
þocsaue to form þart.

out
opaodion in chieh ha metal gets
Dnausing Quti This is the adueion in
enos-Aeional
withh th
the chos-getional
to inease
Jhis is applied
enpense
ef the sboek at the
 Ihe LxeeB5 matal added to he stoek to ense Comblate t
he diz eavity in the Pinisking Lmpnesion is calld fla
Flash acts foom imp act flas nom ha
finishingimpmession a
flos of matad.
Ty þes i ) Hand Fonging
2) Hammsn Fonging
a) Drop Fonging
4) Pre s% Forg rg
5) Machine Forgng
) Roll Forging
r Open-die Fonqing
for ging
-Frietion Fonees
Die

Wookpiece enaling
Die

(a) 6)

Oþan-die onqirg js a hot fonging boocos im which matal is shohed

batucn lat ßn ample contoSad aies.
þocsing
hamning
In open die fomging Hhe dies donot completaly
coveh the csonkpica
Insteod, thae asu ope spaces that alow aious ashects of the
workiece

Heb shofs, solid shafta (zpindles natona),

Hollouw ylindniead ahabes, wAay coithe Jangth muce
Wa u diamatoz of the pot ngth, we! thiek ne s itenna
& outh diamater can be vried as neadal
Contou- fon mad matal shell ike pmesuoe- veyals , whiel may
ineonponate extuded no zz las and othe desig
 FORMINa
OPen die fonging
Adanlag
Impnoed fotid gue Sasistoncs
Comtiows grain fioo
Longoh bnt ife
Inchuaud stnangth
Less chan ca fvo ids
Finen io3.
Custom shapa desigh capab ili ke3.

wonkpie

Dia Die
Di

1- Start stroka [Link] ef stroke

formad & the cork piace is complatay

In this pnoeas, a

co la) by a punch an opde to ill a die eavity oithout ey

Chot on
Joss e matenial. Jhenefone, þroper contnol of vole ot the bilt

AdaabasDimensións with shates can be

achieved.
imþ pesions
2) Mone pnecige, consistart
to upooduca. naos any shape on tiz
Fon beer su faa firisk.
Rduead rasd fon aditional machining
pooduc
) oat- ffecie fo lage
ßn
 dosed Open
The dias comblataly conap matal ncoY,odl and
in cordaa with ha atmosphana.

cöih éa
eixact
) Usingy enlobud dies dies.
bauie on fat shape
shatos.
) Las Aecnate, mone
) Extneme pnecision, shobes
closaly raplieate th die's design
machining
may be Yaedad to achieve the
dasined shape.
IN) Able o þnouee comslar, Tdead or lango hiccas and
dapieut shapes. Äimplon zhape.
APFLICATIoNs

)INoth antoizate detaibs esarkshofts DLarge Rollens ` hafts &Guans.

Camshats , Grua.
) &upports forn constretion, lag Bnacket a Joint Fting.
column3 & Baams.

Ruddes, ship 19 Maine Engine comporrks 2

fangt, rooln shafts
poopell.

PROP FORG| NG
RAM

UPPER
DIE B1LLET
PAE HEATED METAL

LOWER DIE -FLASH

COMPLETED FORGUNG
LOAD
 is a notal
Drop forgira than hammnad
A wow kpieee js in&a9ted nto a die &
ssumad the shae of ha die.
Jh lour die is a stationay pant, hile the ubpr pou
moving hammer, droppod Gnto the oopkpieea im ond
defom it
Dn op foging car be penfoomud bo th at high on ambient

dop fonging emes fron dnophing haavy ham

Jhe n0me

matal to da foom it & s habe it ànto thee de bioed

hammaort
L. Open die drop fonging
2. clocad die drop forgig

Dåuparior strngth & dusakility

) Enhaned st ractual integay

in matal anlecion
Vansodiäity
v) Design
VI) Smpooved Oonain toutuse & muchanical poopert.
AFblicadiong,

(u) Lavehg
Guos

Connacing Rrods

(v Podal rank3
Gusan Blark.
 &toek

Fuleing

Edqing
Bnding

pkockirg
Finishing
 1. Folling inpesion
im : Forming
Vo naduee the 8to cdk to the doainal siae.
edging Rachuined to qohen he ezact aneunt of mstariall
ruquined
at eac cDS - Sacdion of the fiish compomant.
3 krding: Raluined 4on the pords ahieh has koent shape

obtainad, dhe matial is allocsd to have One O

blocking impression ohare it ccduines te shase vey

Taasn to inal OYe.
5. Fires
Final inþnamion cwhar the actual shab aduined is
obtained.
6.

Joimring Jhe extna flash one ant anound

usble.
he fmgig
fom.
is tnimnad
to qet he fonging inn the
 Force
Forg'gopen -die onginq
ongiu onaion Onn
he fonging fone in
stimated by Ahe fonmuda
indrical wonkþiree can be

F=T
the material
whane
p= Fovs stness of
matail.
h aight of tha fo uspealial,
hadius &

cyindieal slug mada of 3O4 stai nles sal

A 8olid lo0 mm keight. If is ud
dia moter
tamperatube by open die fogy
kaight by 50% at room
wifh plat dios. Asaumorg co-cficient of fricion
fno Floo stoess ct 1ooo MPaoSOT
tha &tnoka.
eoleulate th at the end of

Ago)=s mm
0-0 m
2hl00mm =O.| m
u=o..
= 1000x lo Pa

21a05,150 .42 N
21 205

>o.015)«o-t =r< o.05

=[Link]
3=o-0l25
:.f =lo00
3x0-o5

|F= 45 MN
 Poss

the pnocAM of
gnodualiyehangg
eompresirg the matal bla ts
b/w to aies Hhat a
shape by
aither
mechanica y manipuladad.
Apressw
fonging a vasntieal nam to ably gmadual, contnollad
to adie holding a cwonkhi ace -

but it Uses &low

similan pnocas o do fonging,
nstead of a ries of blous.

mave mant of the sam penatnatas deaper ito the p30

olr undgoes urifonm plastie dafomation
that the

1. Mechanical þreNS
2. Hydrautie þooss.

ht noti plastie da foomation

Adantagas tongth [Link]
Ruducad de fochs
oþratons
Mecharieoal pmosnties
Jneat mants
Post Fongra eoaistene
Cost saving
Die Life span
Highee paoduclivity
Paoduees conplex desiqha
Matials
Pnocess Contpol
cNe Automation

Apleationo. 1. Automatke forging

coins e siles
cielos.

Impreion Dia Fonging

 fonging isis aa metal de for mation tachriua ini ahich
1. Smpoemion die fonging
a billet ia comþnessid bl two sets of die to fonm
eompler þt.
2 Impnesionufens to the 'pre-cut pnofil of the dios ued
the fonging pnoes, whieh are usto mi zal bare!e
tha þart that is being
being pnoduced.
3. Dingþne-detamined
the pnoa ss, a pne-cut billat that 's baan haatol to
a temþaatuse ibacsd bo too ats
eustom dies |coclirg
prodl.
As þrevioualy mantionad , each die contains a pne-eut prafi.
2

(on cavity) that snbles cwhat the final bnoduet oil sock
lie.

Adverntoges: <ffective fon shaping oluminin staal, titaian a

widi ange of metal alloys
the hot matal
By enclosig
 nincipl fongig -de desa
of
kigh produetion shape
omporants. mance panfon
innovodive
flashless thtehe forfon pnocasscas pro fonging
at
workpiece
tadionahyl (sDie
Pureh
Fonging
P'oeeision
FORMING
 It nbnmally maans close-to- fnal form clsoA-tolanance
fonging special tbuno legy but a ufinsa mant ot
technifues to a point whana. the þeunts ean bo
usad with iH subakant machining
Pnecition fonging has so hig hen eduinemand the sunfaca,
dimens ional tolehamea and shobe
Cost aving of ass moteria and thus
wsd..

Pne-eondiion fon Aueostul oppicalion of poeci ei or.

1. Input mataial

3.
3ooling
4. domaotua
a- Lubnication
lonventio nal v Psucióien Fongig
Flashle
Forging Uppen
flash
Uppen die Punchh fongig
Fongg
Bilt
Flosh
Louer
die

Louser
puneh

(© Stat of stnoke End of stnok

Adverloqs:
Higk mataiol dilizationi As thane is no flach, aceonaina to the da uignad
þroese6 , mateial wil ba fong ed into desinad
shape at plastie dafoomali on .
3.
Grood coonkig ponforomanca
Fon preision forgings wi thout flash
S Cemplieated shabe pat. fibna
High pnecision.
 Goain Flous

CASTINGT BAR STOCK FORGUNG

(No gmain plow) (oro ain flow (3pus gmain flaa)
bno kan by machiring)

is that gmain flow eam be contnolled Pnocn

COINING PROCESS

1.

FORCE
WORK WORk
DIE DIE

col wonking þr ous fhot usesa gmeaut dal

a fasea
to a die.
to plasticsly da poom cnfonms

die and punch. By using did aml punch,

the
b Tt eonait ts of
imprumion & ehaoted on mtal.

Jhe matal flows plasticay ond suaezad -to the ahate Bhekoen
and die.

Ihe type of impness iove is fonmed by compnesive Ponees. Jr

obtained both aide oil be difpunt.

Advantaaa eohsistent manne

º Poovides oeeuhate bends na

Doenct Jauine espenie machinery
Jhh cwonk hasndened nface
abnasion.
o Eliminate the racd fon comþer Pirsshing pnoem
 plastic Radueas the nain Aize

Lodustoial Jplieati ons:

coins & madallions.

Moking bodqes, bultors, frecitior-anangy poing

Moking complex elaetaonie paot.
HUBBINGL
Proces
Die
manujocteing
Pnes Ram
Handend stael u

Work
Holdn

Vhis þnouys eonsists of pnaMirg handened hunch with a ponticulan tih

guo matry into the guonfoca of a bloek of maal

HEADIN
proas b which tock .Cyiatly
luadig
yllindicall), is uput at is end in iondan to inchease the ehos
in this
Laci o of the motenial
Jhis maal may be hot, bt is of ten a cod coorig

the strogthaning ftha matanial

ojenation.
Cold oil toaka advandage
bn he woekal

ad afplications, buodirg, is masty panfo mad

Fon typitad industei
Roriaordoly ncludi ng nails, ehess
LALd
extenaivayin Hhe pooduckione of fastena
bolts.
 section
1fonos

PUNCH
DIE
FORCE >pUNCH
$ FORCE

WIRE
STOeK

Lengthh < s(width) FASTENER

HEAD
WIRE
STOCK

SWAGhNG PROCESS

DIE

B lank

ROLER

also krown as 0Tby sLog ging þoces in whih, od

1. St"
made by other þnoses is hell stationat
coonkpiecL Ni otata anounb it.
die and movable dier
a

componants which sde

2- This notaing die has sone ecspnocaig
he co ork piece ot a nate L0-2o stooke be
to btuike

blocas
3. Man
jonm a cauy
t 3 is notay operut ion
fo diamter
2. Jhis pnoess is linited
gLod ard ie. oconding
 ORBITAL FORGlNGL

uPPER DIRECTION OF
UpHER bIRECTION OF
DIR
DIE RO TATION RoTATIoN

WORK wOAK
LOWER DIE LovWER

Onbifal fonging and'

fongi"g
die
a it narels in a onbital bath

Jhis upen die meroes on an in elinad aris, and

at a dims
it wil y fonee to a small hontion o the conk

Ony a Small o< aontat, uduces foqirg doods to only 107. hat
convent onal onging at the end of tha stroka
y eonventional
(
Poo 5onbital

displace ment
com pannts cwith -siamatn angeo.

at a time, louen foas

&inee
roiL.
it doesnot pnoduee a

Anotker ad vantage :
ISOTHE RMAL FORING7

mola.(Ti) = Jemperatue of the wonk( )

Jemperatwe ef the
FORCE
DIE

wORK,Ta
DIE
 attempts to
is a hot wonking bnoss that
at ite um ele votod temparata
maimum
maintoin the wosk þile
hout the entine opnation. G)
thoug
P Jhis is achieved by huating the
die to the tamp. o sligkthy 6)