Deformintion Forging

Deformation Processing & Forging Introduction
ver. 1
ME 6222: Manufacturing Processes and Systems Prof. J.S. Colton GIT 2006
Overview
Types of Deformation Processing Forging Wire drawing Extrusion Rolling
Types of deformation processing

Forging Wire drawing Extrusion 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 Window frames
Railroad engine connecting rod
10
Typical product dimensions

Small:
coins surgical wire
Large:
power plant turbine shafts aircraft landing gear
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Aircraft landing gear
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Process characteristics
Material is deformed
improvement of material properties
grain refinement grain orientation work hardening
t = o
Material is conserved
minimal trimming and machining
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Important parameters
Plasticity Friction Elasticity negligible
usually much smaller magnitude than plastic deformation
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Plasticity analysis
Slab method
plane strain plane stress
Forging Platen Forging force Forging force Platen
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Strain hardening
t
t = on
fracture
K Y 1
Tresca (maximum shear stress) yield criterion: flow = flow / 2

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Energy / unit volume (u)
u = flow d = flow d
0 0
= 2
by Tresca (maximum shear stress) criterion
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Working temperature
Recrystallization temperature = 0.5 Tmelting (K)
Cold: T < 0.4 Tmelting(K)

strain hardening effect no strain rate effect
= K
Hot: T > 0.6 Tmelting(K)

no strain hardening effect strain rate effect
& = C
m
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Forging
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Forging
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Old Hammer Forge
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Forging
Part formation by pressing between dies
Dies are hard metal shapes
Temperature
Hot (usually) Cold
Dies
Open (no lateral constraints) Closed (lateral constraints)
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Open Die Forging
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Ring Forging
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Open die forging

Forging force Platen Forging Platen Forging force
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Closed Die Forging
26
Closed die forging

Forging force Flash Forging
Forging force
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Forgings
Coins Landing gear Crank shafts Turbine shafts
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Forging presses
Large machines
hold dies form parts
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Press types
Hydraulic presses Mechanical presses Screw presses Hammers
gravity drop power drop counter blow (two rams) high pressure gas
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50,000 ton press
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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)
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Forges
Schematic illustration of the principles of various forging machines. (c) Knuckle-joint press. (d) Screw press. (e) Gravity drop hammer.
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Dies
Final part shape determined by 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
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Forging hammer capabilities

Moving mass Energy at (kg) 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
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Forging press parameters

Load c a p a c ity M e c h a n ic a l p r e s s e s O p e n -b a c k , in c lin a b le H ig h - s p e e d , s tr a ig h t s id e L a r g e r s tr a ig h t s id e T r a n s fe r p r e s s e s F o r g in g p r e s s e s 1 5 0 - 1 ,2 5 0 kN 3 0 0 - 2 ,0 0 0 KN 1 - 6 MN 2 - 40 M N 3 - 80 M N S tr o k e s p e r m in u te 200 - 100 2000 - 200 100 - 20 50 - 10 100 - 30 10 - 60 20 500 Pow er (k W ) 3 - 15
H y d r a u lic p r e s s e s U n iv e r s a l F o r g in g p r e s s e s
4 - 25 M N 2 - 500 M N
150 1000
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Hot upsetting machine parameters

Rate size (mm) (upset diameter) 25 38 50 75 100 125 150 175 200 225 Forging force (MN) 0.5 1 2 4 6 8 10 13 16 20 Strokes/min 90 65 60 45 35 30 27 25 23 20 Power (kW) 5 10 15 25 40 50 60 90 110 150
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Forging steps
Prepare slug
saw flame cut shear
Clean slug surfaces

shot blast flame
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Forging steps
For hot forging
heat up and descale forging make sure press is hot
Lubricate
oil soap MoS2 glass graphite
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Lubrication purposes
Reduce friction Reduce die wear Thermally insulate part
to keep it warm
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Forging steps
Forge Remove flash
trim machine
Check dimensions Post processing, if necessary

heat treat machine
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Effect on grain structure

Large grains are broken up. Grains can be made to flow.
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Main forging defect

Surface cracks
due to sticking and barreling, leading to tensile forces on the surface.
forging operation
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Forging Defects
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Summary
Types of deformation processes Material deformation review Forging introduction
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Deformintion Forging

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Deformintion Forging

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Deformation Processing & Forging Introduction

Types of deformation processing

What is deformation processing?

Railroad engine connecting rod

Typical product dimensions

Aircraft landing gear

Tresca (maximum shear stress) yield criterion: flow = flow / 2

Energy / unit volume (u)

Cold: T < 0.4 Tmelting(K)

Hot: T > 0.6 Tmelting(K)

Old Hammer Forge

Open Die Forging

Open die forging

Closed Die Forging

Closed die forging

50,000 ton press

Forging hammer capabilities

Forging press parameters

Hot upsetting machine parameters

Clean slug surfaces

Check dimensions Post processing, if necessary

Effect on grain structure

Main forging defect

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