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Module-II of PDPTLecture Notes of Chinmay Das
 7
2.2 DROP FORGING DIE DESIGN
Factors to be considered
i) Number of Impressions
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Number of impressions or stages necessary to achieve the required flow direction so as toobtain requisite strength.
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Normally fullering or rollering, edging and finishing impressions are necessary.
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If required, then other impressions like blocking or semi-finishing, bending, flattening,trimming etc. can be arranged.
ii) Flash and Gutter
The excess metal added to the stock to ensure complete filling of the die cavity in the finishing impressionis called Flash. It acts as a cushion for impact blows from the finishing impression and also helps to restrictthe outward flow of metal, thus helping in filling of thin ribs and bosses in the upper die. The amount of flash depends on the forging size and may vary from 10 to 50 %. The flash flows around the forging in theparting plane.Figure 2.2.1: Proportion of flash in drop forgingForging load is greatly influenced by the flash thickness and width. The load can be decreased byincreasing the flash thickness but metal lost in the form of flash (it is a waste) also increases. The forgingload also decreases with an increase in the average thickness of the component. In addition to the flash,provision should be made in the die for additional space so that any excess metal can flow and help in thecomplete closing of the die. This is called Gutter. Without gutter, flash may become excessively thick, notallowing the dies to close completely.The flash land provided in the die should be about 3 % of the maximum forging thickness (0.5 to8.0 mm). If the flash land is too small, then the energy required for the forging increases because of theexcess metal trapped in the finishing impression and flash land wears out quickly. Similarly, too high aflash land lets the work metal to flow into the gutter and thus the die cavity gets unfilled.
Flash GutterStock size, mmWidth, mm Thickness, mm Width, mm Thickness, mm
Up to 35 4.5 0.8 25 3.036 to 50 5.3 1.0 25 to 32 4.551 to 65 6.5 1.5 32 to 38 4.566 to 75 8.0 2.0 32 to 38 4.576 to 100 10.0 3.0 38 to 44 6.5Table I: Recommended flash and gutter sizes
 
Module-II of PDPTLecture Notes of Chinmay Das
 8
Figure 2.2.2: Proportion of gutter in drop forgingThe wider area of the gutter (magazine) is usually made in the top section of the die. If the forgingis of such a shape that it must be turned over through an angle of 180
0
when trimming the flash away, themagazine is made at the bottom. For greater slowing down of metal (to allow it to fill up the impressioncavities better), the bridge of the gutter is made with a barrier. If much metal is expected to flow to flash, alarger magazine is provided. A wedge-type gutter decreases the flash.
iii) Stock
The drop forgings do not get upset and therefore the stock size to be chosen depends on the largest crosssectional area of the component. To get the stock size, the necessary flash allowance is to be provided overand above the stock volume (after adding all allowances). The stock is either round, rectangular or anyother section depending on the nature of the component. From total volume of the component and flash, itis possible to determine the length of the stock. The stock in the die is to be moved from one impression tothe other, and hence a tong hold of about 50 to 60 mm is added to the stock length.
iv) Fullering Impression
The first operation to be done in drop forging is to draw out the stock at the necessary portions by strikingthe metal with sharp and rapid blows. The amount of drawing out depends on the differences in themaximum and minimum cross section of thecomponents. For smaller drawing out applications,the fullering impression is made along with the otherimpressions in the same die. The stock is fullered tothe required shape in approximately 4 to 5 blows inthe fullering impression. The stock is turned 90
0
 between each blow and is slowly progressed to obtainthe required fullered length. The major considerationin this stage is to keep the two die halves away fromcompletely closing and to allow for smooth flow of metal. As a rough rule, the gap between the twoimpressions should be kept equal to the thickness of forging less 1.6 mm to 5 mm. The length of impression could be either half of the stock lengthwithout flash and tong hold or 25 % of length of fulleredFigure 2.2.3: Fullering impressionstock whichever is less. The distance between the relief portions of the impression should be twice thediameter of the stock.
 
Module-II of PDPTLecture Notes of Chinmay Das
 9
v) Edging Impression
 The edging impression or perform, gathers the material as required in the final forging. This gatheringhelps in proper flow of metal and complete filling of the die cavities in the later impressions. The performshape also helps in proper location of stock in the blocking impression. For irregular shapes with largevariation in cross-section, and which are extra long compared to other dimensions, it is very difficult togather the material. In such cases, it would be desirable to have two edging impressions.In an edging impression, the area at any cross section should be same as that of the correspondingsection in the component and flash allowance. For complex shapes, the graphical method is adopted forcalculation of cross sectional area. The following procedure may be used to arrive at the perform shape.
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The plan and elevation views of the forging should be drawn side by side to a convenient scale,preferably full size. On the same views, the flash outline around the component is laid out.
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A baseline is drawn parallel to the longitudinal axis of the component, at a small distance from thecomponent views.
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The component is divided into a number of elements by horizontal lines. The choice of elements isbased on the geometric shape of the component and the variation in the cross-section. If the crosssection is uniform over a length, then only one section is enough. Whereas, when the cross sectionis changing drastically, then it may be necessary to divide the component into a large number of sections over the change.
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The cross sections of each of the elements chosen are calculated by simply multiplying theelements in the two views of the component. The areas of these various elements can be plottedfrom the base line to any appropriate scale. These plotted points are joined with a smooth curve. Inthis process, if there are any abrupt variations in the areas, then some more sections may be chosento gat a smooth curve.
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The flash area provided at each of these elements are calculated and added to the areas alreadyplotted.
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Having known the cross sectional area of the component and flash at each of the elementalsections, the radius of perform at these elements is given by the formulaRadius, R = { area / 
π
}
0.5
 Figure 2.2.4: Graphical method of finding the edging impression of a drop forged component
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