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Forging Basics
Introduction to Forging Process + A handy glossary of Forging Terms Good for...
From Al Engg
Module-II of PDPTLecture Notes of Chinmay Das
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2.1 FORGING OPERATION
Forging is the operation where the metal is heated and then a force is applied to manipulate the metal insuch a way that the required final shape is obtained.Figure 2.1.1: Forging machine Figure 2.1.2: Grain structure in forgingTwo types of operations are used in forging in order to arrive at the final shape. They are as follows.
Drawing out
: This is the operation in which the metal gets elongated with a reduction in the cross sectionalarea. For this purpose, the force is to be applied in a direction, perpendicular to the length axis.
Upsetting
: This is applied to increase the cross sectional area of the stock at the expense of its length. Toachieve this, force is applied in a direction parallel to the length axis.Because of the manipulative ability of the forgingprocess, it is possible to closely control the grain flow inthe specific direction, such that the best mechanicalproperties can be obtained based on the specificapplication. Some examples of desirable grain flowdirections are given in the adjacent figure.In the crane hook it is possible to get the twotypes of grain patterns by proper arrangement of operations. The grain pattern obtained without bendingis shown in fig.2.1.3 (a), where as the one in (b) isobtained by bending after drawing out. As a result, thegrain flow is also bent along the hook and thus providesthe necessary strength for lifting loads.The gear blank shown in (d) is obtained byupsetting the blank and then finish forging, whereas theone in (c) is obtained without upsetting the blank. Thisprovides radial grain flow which is essential for goodstrength in gear teeth for several applications.Figure 2.1.3: Grain flow directions in forging
Module-II of PDPTLecture Notes of Chinmay Das
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Forging Design Considerations
Parting Plane
: A parting plane is the plane at which the two die halves of the forging meet. It could be asimple plane or irregularly bent, depending on the shape of the forging.
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The parting plane should be the largest cross sectional area of the forging, since it is easier tospread the metal than to force into deep pockets.
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A flat parting plane is more economical.
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It should be chosen in such a way that equal amount of material is located in each of the two diehalves.
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It may be required to put more metal into the top die half since metal would flow more easily intop half.
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If the punching of hole, which is perpendicular to the parting plane, is required then it may benecessary to choose a parting plane which distributes the hole evenly and provides sufficientstrength to the punch. The below mentioned figure shows one possible parting plane whichsimplifies the lower part of the die. But the punch in the upper die half becomes excessively longand may buckle. By changing the parting line as shown in the next figure, it is possible to punchfrom both sides, thus reducing the machining. This also provides a smaller height to diameter forthe punch increasing its rigidity.(a) (b)Figure 2.1.4: Parting line to reduce the depth of a punched hole
Draft
: It is the taper put on all the forging sides arranged parallel to the travel of the press slide or hammerram. This makes it easier for the metal to fill up the working volume of the die impressions and facilitatesthe removal of the forging. Standard practice indicates the use of 2 to 12
0
draft angles depending on thetype of die, rib height, and the material to be processed. Internal surfaces require more draft than externalsurfaces. The forgings of non-ferrous alloys need smaller drafts than the steel ones. In upset forgings, thedraft problem is minimized because the part is held securely by the gripper die during the punch withdrawaland the gripper itself gets opened to release the component. So for upset forgings smaller value of draftangle is considered.
Drop forgings Upset forgingsDraft positionHeight orDepth (mm)Normal( degree)Close(degree)Normal( degree)Close(degree)
Up to 25 5 to 7 3 to 7
Outside
Above 25 5 to 10 3 to 73 to 5 2 to 4Up to 25 7 to 10 5 to 8
Inside
Above 25 8 to 12 5 to 95 to 7 4 to 6Table I: Recommended draft angles
Fillet and Corner Radii
: Since forging involves flow of metal in orderly manner, therefore it is necessaryto provide a streamlined path for the flow of metal so that defects’ free forging is produced. When two ormore surfaces meet, a corner is formed which restricts the flow of metal. These corners are rounded off toimprove the flow of metal. Fillets are for rounding off the internal angles, whereas corner is that of theexternal angle. Let us consider the flow of metal over a corner as shown in the figure 2.1.5(a). Because of large corner radius provided, metal is allowed to flow smoothly into the pocket. But when corner radius issmall or not provided as in figure 2.1.5(b), the metal flow is first hindered and when it finally enters the
Module-II of PDPTLecture Notes of Chinmay Das
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cavity, the metal would fold back against itself forming a defect called lap or cold shut. Nominal fillets andcorner radii are taken from the tables to suit the weight and required accuracy of the forgings. Sharp filletsand radii increase the tendency towards forging defects and accelerate the die wear. To avoid this fillets aretaken to be larger than corner radii.Figure 2.1.5: Effect of corner radius on the flow of metal
Depth orHeight, mmFillet, mm Corner radius, mm
15 5 2.525 8 4.040 12 4.550 15 5.065 18 5.575 20 6.0Table II: Recommended fillet and corner radii for drop forgingsUpset diameterStock diameterFillet, mm Corner radius, mmUp to 1.25 6.5 6.51.25 to 3.00 3.5 3.5Over 3.00 3.0 3.0Table III: Recommended fillet and corner radii for upset forgings
Shrinkage Allowance
: The forgings are generally made at a high temperature of 1150 to 1300
0
C. At thistemperature, the material gets expanded and when it is cooled to the atmospheric temperature, itsdimensions would be reduced. Hence a shrinkage allowance is added on all the linear dimensions.
Length or width, mm Commercial, mm Close, mm
Up to 25 0.08 0.0526 to 50 0.15 0.0851 to 75 0.23 0.1376 to 100 0.30 0.15101 to 125 0.38 0.20126 to 150 0.45 0.23Each additional 25 Add 0.075 0.038Table IV: Recommended shrinkage allowance
Die Wear Allowance
: This allowance is considered to account for the gradual wear of the die which takesplace with the use of the die.
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Forging Design Considerations
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