2 F-
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ஸ்
MODULE 2: FORGING
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Forgingis a type of manufacturing process wherein a metal
is heated to its plastic State Cabove recrystallization
Temperature) and then deformed to the desired shape and
size by the application of compressive forces through a
hammer, press, or rolls
If the Compressive force is applied manuallg by
using specifie tools,called hand forging
it is
If the compressive force is applied using macines it
is called Power forging.
Most forging operations are carried out hot athough
Certain metals
at
may be cold forged. forging is peyomed
with melal, or near room temperature
Typical parts made by forging in modern industoay
Includes alreraft Components like landing gear, shaf ts
and Turbmes; Automobile and Railrood
for Jet engines
es
Components lime Cankshayts, levers, gears, Connecteng
rod's, hand tools like chisels, rivets, Screws and boits
and a wide variety of components for other applications.
>
Forging is generally employed for those comporents
which require high strengih and resistance to shock or
Vibration and uniform properties.
Forging Should be carried out at temperature high enough
to that the metal can be easily deformed by applied
force. It should be above recrystallization temperature
to avoid work hardening but should not be too high
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Go as to cause excessive grain growth and haudening.
Low carbon steel and many of the alloy tool steels
and stainless steels can be forged. Aluminium,
and copper alloys lend themselves to the
magnesium im
forging operations.
The forging temperature required for the Non-ferrous
materials are much lower Than that for ferrow materials.
However, many of the high -allay nonferrous matecials
present problems of die wear.
The raw material for forging is usually a bar, billet
or blank. By forging original crystals are deformed
and many of the precipitated at
comtituents are
high tempeature which again becomo soluble in the
selid iron on freozing thestry increasing the local
homogenity of the matesial.
→ Smaller parts Smish forged in preumatic
are usually
power hammes, laiger pauts in air and steam foging
hamrers whesas verg heavy pants are forged
hydraulic presses
The Primary dfference between vausas forging
metrods is tee rate at which the enagy is
applied the wornpiece. The forging hammer has
to
a relatoely higher sate of diformation while the
hydiaulic press hasa relatwely slowe sat o) dyemater.
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Duoing the forging precEss whether preliminary or
finishing the flow of meral is affecred by
(i) Degree f deformation ( Strain)
(1!) Rate of
deformation of
(Rate of steain)
(ii) Temperature-
→ Trese factors laugely determine the flow stress
(nesistance of metal to deformation).
The flow of metal is also affected by
(i) Nature of meta!
(ii) Composition of metal
(iis Metalliugical stacture of the meta!
a) phases ; bs grain size o) Segregation
CLASSIFICATION OF FORGING PROCESS
Forging process can be Classified by the degree
to which the flow of work matesial is comtrained
aluring the poocess.
The thiree broad Categories of forging processes are
as open forging,
die
b) Impreesion die forging
6) Closed die forging (Flashless forging)
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a) OPEN DIE FORGING:
Also called as Smith's forging or flat die forgiog
Carried out between flat dies that do not enclose
the workpiece
Most open-die forgings are produced on flat- V or suojang
dies. Round Swaging dies and v dies are used in
pairs wirh a flat die.
a) FLAT DIES (b) V- DIES C) FLAT DIE Y
V DIE
The top die is attached to
the ram of the press
Bottom die is attached to the
hammer anvil or to the press
d) SWAGE DIES. bed.
nt a
to ovie orkpie *
As the workpiece is hammered or
ator n w
pul andpos itio Top die presed, it is reparedly
Mani manp ulaed
emoving between the dies untel hot wo
Hot forcer the meral to fenal dumensbns.
Workpiece
m die
Botto
oranvil
(fizоp(
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Suppot SuppORT
WORK
Lathe rwing to neai net shape.
→ Open die forging, in its Simplest foom genually involves
Placing a Solid Cylindrical workplece between too flat
dies (platens) and neducing its height by complessing
it. Tnis process is known as upsetting
Under Ideal conditions, a solid cylinder depooms as shown
known as homo geneous depoomation
Die
hf
Workpiee hi
di
Die
Figure below shows deypema tion in upsetting wirh foiction
as the die-workpiece inteyaces. Specmen dwelops a bavd
Shape. о.
friction foк
hf
h
di ↓
minemized by an
→ Bareling Caused by fricton can be
effective lubricant
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Advantages bo open-die forging
Simple to operate
Ci) Simple for production Volume
low
(i Irexpensive booling and equipment
wornpiece Sizes can be used.
(iv) Wide range of
LIMITATIONS
C1n Suitable for Simple shapes only
CiD Can be employed for Snort run production only.
C1) Difficuit to maintain moderately close tolerances.
(iV) Less Contool in deteiroining
detemin gran flow, mechanical
properttes and dimensioos
C. Fairly Sniled workers ae requtied
is ofben required, fenal cost of
(V Since
may te higher than otha forging mRods.
I MPRESSION DIE FORGING!
→ In impression- die forging, the wormpiece acquires
the shape of the die cauities Cimpressions)
while it is being upset between the closing dies
→ When
two die halves close, the impressions form
a carity whese stape is sinear to that of
desired product.
→ workplece undergoes plartic deppomation untl its
enlauged sides fouch the side walls of the die.
-→ The do not fally
two die halves Close with each
other, imiead designed with a small gap between
them.
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* This gap is referred as Flash gatter
TOP DIE
(MOVING)
FLASH
HOT WORKPIECE
GUTTEe
BOTTOM DIE
(FIXED)
FORCE
GAP
FLASH
→ In impression die forging, the hot workpiece metal
is placed in the bottom die, which is attached to the
anvil or press bed.
- Top dre attached to a secipsocateng dam of the machire.
is
fal ls ca us in g the top die to force the
Th e sa m do on
e blocKs.
of the di
heared metal to fill the contours
pa ct th e wo rk pi ec e sevesal tumes to
The oam may im e filled
of the Contours ar
ensure all
logether for froishing srep, an y
when two dies come
present is squeeged out of the di
e
excess metal
Cawittes as a thin ribbon of metal caed flash
when forging is completed, flash is trшор о
Suitably
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The flash cools more rapidly than the rest ofe
metal be ngg stoonger than te
bein
material; this cool prevent ash more fl
ips
metal in the die he
to
from forming.
completely cavity
ful die
This also forces the metal to
leted fiash is toimmed oNq
when forging is comp
Suitably
Advan tages
Suitable for smal and medium sized components
*
* pooduces dimensionally accurare forgengs
fenish can be obtauned
Good Sufaco
ace
*
of die caurly as flash,
Excess metal is forced out
pressure build up in the av
ity,
Re eb y clwrinating the dies.
there Impoving the ise &
бy
Dis-Adrantages:
メ Not Suitable for lauge sized Components
A Inittal die costs make the poocess suitable for mass
production only
CLOSED DIE FORGING
Closed die forging is a poecision forging in wbich the
enture volume of the work material is enclosed withen the
die and no matelal is allowed to escape foom the
mould during the forgrng process
* As a result, No flash is foomed and hence called as
Flashless forgeng