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TALAT Lecture 3402: Forging Process

TALAT Lecture 3402: Forging Process

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Published by CORE Materials
This lecture helps to understand the basic principles of die forging and the characteristic features of special aluminium die forging processes. It aims at learning about the basic design of dies in order to obtain optimum part qualities and tool life. General understanding of metallurgy and deformation processes is assumed.
This lecture helps to understand the basic principles of die forging and the characteristic features of special aluminium die forging processes. It aims at learning about the basic design of dies in order to obtain optimum part qualities and tool life. General understanding of metallurgy and deformation processes is assumed.

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TALAT Lecture 3402
Forging Process
17 pages, 20 figures
Basic Level
prepared by K. Siegert, R. Malek and R. Neher, Institut f\u00fcr Umformtechnik,
Universit\u00e4t Stuttgart
Objectives:
\u2212 to understand the basic principles of die forging and the characteristic features of
special aluminium die forging processes
\u2212 to learn about the basic design of dies in order to obtain optimum part qualities and
tool life
Prerequisites:
\u2212 general understanding of metallurgy and deformation processes
Date of Issue: 1994
\ue000 EAA - European Aluminium Association
TALAT 3402
2
3402 Forging Process
Table of Contents
3402Forging Process....................................................................................................2
3402.01 Principles of the Forging Process................................................................ 3

Fabricating Processes of Forging..................................................................................3 Processes for Changing Cross-Sections.......................................................................4 Processes for changing direction..................................................................................5 Processes for Creating Hollow spaces..........................................................................5 Separating Processes.....................................................................................................6 Die Forging Processes...................................................................................................6

Open-Die Forging................................................................................................... 7
Die Forging.............................................................................................................. 7
3402.02 Special Forging Processes for Aluminium.................................................. 8

List of the aims of various special die forging processes.............................................8 List of characteristic features of precision forging.......................................................9 List of characteristic features of high precision forging...............................................9 Characteristic features of closed die forging without flash....................................... 10 Characteristic features of isothermal forging............................................................ 10

3402.03 Forging Dies.................................................................................................11

Types of Forging Dies................................................................................................ 11 Parting of Forging Dies.............................................................................................. 12 Rules for design of partings of forging dies.............................................................. 13 Die Inserts.................................................................................................................. 14 Fabricating Forging Dies........................................................................................... 15 Failure and Damaging of Forging Dies..................................................................... 16

3402.04 Literature:....................................................................................................... 17
3402.05 List of Figures................................................................................................. 17
TALAT 3402
3
3402.01
Principles of the Forging Process

\u2022 Fabricating processes of forging
\u2022 Processes for changing cross-sections
\u2022 Processes for changing direction
\u2022 Processes for creating hollow spaces
\u2022 Separating processes
\u2022 Die forging processes

Fabricating Processes of Forging

The term forging is used to define a group of processes which are mainly forming processes (see Figure 3402.01.01). Additionally included are processes of separating (splitting) and joining, if large or complicated workpieces are built up out of individual parts. The exact processes of separating and joining are not listed here in detail. According to the characteristic differences in free forming (or unrestricted forming) and die forming (restricted forming), forging can be divided into open-die forging and die forging.

alu
Training in Aluminium Application Technologies
Fabrication Process of Forging
Source: K. Lange
Separating
Forming
Joining
Tensile forming
Bulge forming
Bulge forming
with mandrel
Free bending
Bend forming
Die bending

Forming by ben-
ding with linear
motion of tool

Shear
forming
Displacing
Offsetting
Bending by
buckling
Open-die forming
Punching
Through punching
Piercing with a
hollow mandrel
Embossing
Hobbing
Closed-die
forming
Drawing out solid
and hollow bodies

Expanding
Spreading
Upsetting
Heading
Stepping
Radial or rotary

forging
Rolling

Rollforging
Discrolling
Ringrolling
Lateral rolling

of shaped parts
Cross rolling of
shaped parts
Setting
spiral
twisting
Twisting
Indenting
Extruding
Fabrication Process of Forging
3402.01.01
Compressive
forming
Drawing out in a
Radial forging in
a die
Upsetting in a die
Closed die forging
without flash
Impression die
forging with flash
die
Fullering
Solid forward
impact extrusion
Backward cup
impact extrusion
Solid lateral
impact extrusion

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