UpsetForgingDieDesign

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Module-II of PDPTLecture Notes of Chinmay Das

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2.3 UPSET FORGING DIE DESIGN

In upset forgings, as a rule, no reduction in cross section occurs and, therefore, the stock to be chosen is of the smallest area of cross section of the component. Also, very small or negligible flash is provided in upsetforgings. Depending on the shape of the upsetting to be done, the number of passes or blows in the die areto be designed. The amount of upsetting to be done in a single stage is limited. To arrive at the safe amountof upsetting in a given pass, the following three rules are to be satisfied to achieve defect free upsetforgings.

Rule No.1:

The maximum length of the unsupported stock that can be gathered or upset in a single pass is notmore than three times the stock diameter. Beyond this length, the material is likely to buckle under the axialupset.Figure 2.3.1: Application of rule one for proper upsetting

Rule No.2:

If the stock longer than three times the diameter is to be upset in a single blow, then the followingconditions should be complied. The die cavity should not be wider than 1.5 times the stock diameter andfree length of the stock outside the die should be less than half the stock diameter. When these conditionsare not complied, the stock would bend.Figure 2.3.2: Application of rule two for proper upsetting

Module-II of PDPTLecture Notes of Chinmay Das

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Rule No.3:

For upsetting the stock which is longer than three times the diameter and free length of stock outside the die is up to 2.5 times the diameter, the following conditions should be satisfied. The metal is tobe confined into a conical cavity made in the punch with the mouth diameter not exceeding 1.5 times thestock diameter and the bottom size being 1.25 times the stock diameter. Also, it is necessary that theheading tool recess be not less than two thirds the length of the working stock or not less than workingstock minus 2.5 times the stock diameter.Figure 2.3.3: Application of rule three for proper upsettingThe above are the absolute limits for proper upsetting. But in practice it may be possible to cross theseabsolute limits.

Location of Cavities

The upset cavities may entirely be kept in the gripper dies or in the heading tool or part in thegripper and part in the heading tool. The choice of location mainly depends on the severity of theupsetting and the convenient location of flash fortrimming. Simple forgings requiring smaller upsettingmay contain the complete die cavity in the headingtool. Also complex shapes requiring severe upsettingare obtained with the die cavity completely in thegripper die.For very simple shapes, one pass may be enough toobtain the final shape, but majority of forgings requirethree or more passes. If trimming of flash is included,then an additional pass is required. All these passes arearranged on the die block in an order and the stock ismoved from one pass to the other sequentially. Whiledesigning the heading tool or the punch to slide into thegripper die, it is necessary to provide clearancebetween the two such that no seizure takes place due touneven expansion or due to scales of the punch and die.Figure 2.3.4: Location of cavitiesThis clearance should be of the order of 0.125 to 0.200 mm. The length of gripping portion of the gripperdie should be maintained between 3 and 4 times the stock diameter.

Module-II of PDPTLecture Notes of Chinmay Das

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Figure 2.3.5: Gripper die section

Stock size, mm R, mm A, mm C, mm

10 5 0.05 0.4016 8 0.06 0.4020 10 0.08 0.4022 11 0.09 0.4025 12.5 0.10 0.4032 16 0.13 0.8040 20 0.15 0.8045 22.5 0.17 0.8050 25 0.18 0.8065 32.5 0.19 1.2075 37.5 0.20 1.20Table –I: Gripper die dimensionFigure 2.3.6: Upset forging products

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