Deform Intro

Deformation Processing &
Forging Introduction
ver. 1
ME 6222: Manufacturing Processes and Systems 1

Prof. J.S. Colton © GIT 2009
Overview
• Types of Deformation Processing

• Forging
• Wire drawing
• E t i
Extrusion
• Rolling

Types of deformation processing
• Forging
• Wire drawing
• Extrusion
• R lli
Rolling

Forging

Wire drawing

Extrusion

Rolling

What is deformation processing?
• Process to make parts without material

removal
• Deformation occurs on parts with L/D ≈1
• High volume

Examples of products
• Connecting rods
• Wire
• Bars
• Wi d
Window fframes

Railroad engine
g connecting
g rod

Typical product dimensions
• Small:
– coins
– surgical
i l wire
i
• Large:
– power plant turbine shafts
– aircraft landing gear

Aircraft landing gear

Process characteristics
• Material is deformed
– improvement of material properties
• grain refinement
• grain orientation
• work hardening
σ t = σ oε n
• Material is conserved
– minimal trimming and machining

Important parameters
• Plasticity
• Friction
• Elasticity negligible
– usually
ll much h smaller
ll magnitude
it d
than plastic deformation

Plasticity analysis
Forging force
• Slab method
– plane strain Platen
– plane stress Forging
Platen
Forging force

Strain hardening
σt
fracture
σt = σoεn K
ε
1
• Tresca (maximum shear stress)
yield criterion: τflow = σflow / 2

Energy / unit volume (u)
ε1 γ1
u = ∫ σ flow dε = ∫ τ flow dγ
0 0
∴ Δγ = 2 Δ ε
by Tresca (maximum shear stress)

criterion

Working temperature
Recrystallization temperature = 0.5 Tmelting (K)
• Cold: T < 0.4

0 4 Tmelting(K)
– strain hardening effect
– no strain rate effect
σ = Kε n
• Hot: T > 0.6 Tmelting(K)

– no strain hardeningg effect
– strain rate effect
σ = Cε& m
ME 6222: Manufacturing Processes and 18

Systems Prof. J.S. Colton © GIT 2009
Forging

Forging
g g

Old Hammer Forge

Forging
g g
• Part formation by pressing
between dies
– Dies are hard metal shapes
• Temperature
– Hot (usually)
– Cold
• Dies
– Open (no lateral constraints)
– Closed (lateral constraints)
Open Die Forging

Ring Forging

Open die forging
Forging force
Platen
Forging
Platen
Forging force

Closed Die Forging

Closed die forging
F i force
Forging f
Flash
Forging
Forging force

Forgings
• Coins
• Landing gear
• Crank shafts
• T bi shafts
Turbine h ft

Forging presses
• Large machines
– hold dies
– form parts

Press types
yp
• Hydraulic
y presses
p
• Mechanical presses
• Screw presses
• Hammers
– gravity
i d drop
– power drop
– counter blow (two rams)
– high pressure gas

50 000 tton press
50,000

Forges
Schematic illustration of the principles of various forging machines. (a) Hydraulic

press. (b) Mechanical press with an eccentric drive; the eccentric shaft can be replaced
by a crankshaft to give the up-and-down motion to the ram. (continued)

Forges
Schematic illustration of the principles of various forging machines. (c) Knuckle-joint

press. (d) Screw press. (e) Gravity drop hammer.

Dies
• Final p
part shape
p determined byy die
accuracy
• Multiple parts can be made in one die
• Progressive shaping can be done in one
die set
• Need to be stronger than highest
forging stress

Forging hammer capabilities
Moving mass Energy at

((kg)
g) strike ((J))
Gravity drop 500 - 5,000 6,000 -
hammers 75,000
Power drop 500 - 18,000 18,000 -
hammers 600,000
High energy 500,000 -
rate forming 5,000,000
Forging press parameters
Load S tr o k e s Pow er
c a p a c ity p e r m in u te (k W )
M e c h a n ic a l p r e s s e s
O p e n -b a c k , 1 5 0 - 1 ,2 5 0 200 - 100 3 - 15
in c lin a b le kN
H ig h - s p e e d , s tr a ig h t 3 0 0 - 2 ,0 0 0 2000 - 200
s id e KN
L a r g e r s tr a ig h t s id e 1 - 6 MN 100 - 20 10 - 60
T r a n s fe r p r e s s e s 2 - 40 M N 50 - 10
F o r g in g p r e s s e s 3 - 80 M N 100 - 30 20 -
500
H y d r a u li
lic p r e s s e s
U n iv e r s a l 4 - 25 M N
F o r g in g p r e s s e s 2 - 500 M N 150 -
1000

Hot upsetting machine parameters
Rate
R t size
i ((mm)) Forging
F i fforce St k / i
Strokes/min P
Power (kW)
(upset diameter) (MN)
25 0.5 90 5
38 1 65 10
50 2 60 15
75 4 45 25
100 6 35 40
125 8 30 50
150 10 27 60
175 13 25 90
200 16 23 110
225 20 20 150

Forging steps
• Prepare slug
– saw
– flame cut
– shear
• Clean
Cl slug
l surfaces
f
– shot blast
– flame

Forging
g g steps
p
• For hot forging
– heat up and descale forging
– make sure press is hot
• Lubricate
– oil
– soap
– MoS
oS2
– glass
– graphite
Lubrication purposes
• Reduce friction
• Reduce die wear
• Thermally insulate part
– to
t keep
k it warm

Forging steps
• Forge
• Remove flash
– trim
– machine
• Check dimensions
• Post processing, if necessary
– heat
h t treat
t t
– machine

Effect on grain structure
• Large grains are broken up.

• Grains can be made to flow
flow.

Main forging defect
• Surface cracks
– due to sticking and barreling, leading to
tensile forces on the surface.
forging
operation

Forging Defects

Summary
• Types of deformation processes

• Material deformation review
• Forging introduction


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Deformation Processing &

ME 6222: Manufacturing Processes and Systems 1

• Types of Deformation Processing

ME 6222: Manufacturing Processes and Systems 2

ME 6222: Manufacturing Processes and Systems 3

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• Process to make parts without material

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by Tresca (maximum shear stress)

ME 6222: Manufacturing Processes and Systems 17

• Cold: T < 0.4

• Hot: T > 0.6 Tmelting(K)

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Schematic illustration of the principles of various forging machines. (a) Hydraulic

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Schematic illustration of the principles of various forging machines. (c) Knuckle-joint

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Moving mass Energy at

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• Large grains are broken up.

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• Types of deformation processes

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