Nama : Rivansyah Prambudi Ahmad

NIM : 1808311

Homework Forging
REVIEW QUESTIONS
19.12. What is forging?
Forging / Penempaan adalah suatu proses deformasi pada bahan kerja menggunakan 2
cetakan/dies, menggunakan benturan dan tekanan untuk pembentukannya. Namun forging
yang orang awam kenal itu menggunakan hammer/palu di pukul kepada logam yang sering
terlihat yaitu dalam pembuatan pedang/senjata
19.13. One way to classify forging operations is by the degree To Which The Work is constrained in
the die. By this classification, name the three basic types.
1)Open-die forging
2)Close-die forging/impression-die forging
3)Flashless forging/True Close-die forging
19.14. Why is flash desirable in impression-die forging?
Meningkatkan pembekuan, meningkatkan resistansi deformasi dan meningkatkan tekanan
yang membantu aliran material ke rongga yang masih kosong
19.15. What is a trimming operation in the context of impression-die forging?
Proses penghilangan flash/pemotongan flash
19.16. What are the two basic types of forging equipment?
Mekanik dan pengepresan hidrolik
19.17. What is isothermal forging?
Suatu proses yang menggunakan konesep hot-forging dimana bahan kerja dipertahankan pada
suhu awal yang ditinggikan saat deformasi, biasanya dengan cara memanaskan cetakan
disesuaikan dengan suhu bahan kerja, untuk menghindari benda kerja yang bersentuhan
dengan permukaan cetakan yang dingin, menyebabkan logam mengalir lebih cepat dan
mengurangi gaya yang dibutuhkan
PROBLEMS
19.14 A cylindrical part is warm upset forged in an open die. The initial diameter is 45 mm and the
initial height is 40 mm. The height after forging is 25 mm. The coefficient of friction at the die-work
interface is 0.20. The work material has a flow curve defined by a strength coefficient of 600 MPa and
a strain hardening exponent of 0.12. Determine the force in the operation (a) just as the yield point is
reached (yield at strain = 0.002), (b) at a height of 35 mm, and (c) at a height of 25 mm.
19.15 A cylindrical workpart with D = 2.5 in and h = 2.5 in is upset forged in an open die to a height
= 1.5 in. Coefficient of friction at the die-work interface = 0.10. The work material has a flow curve
defined by: K = 40,000 lb/in2 and n = 0.15. Determine the instantaneous force in the operation (a) just
as the yield point is reached (yield at strain = 0.002), (b) at height h = 2.3 in, (c) h = 1.9 in, and (d) h =
1.5 in.
19.16 A cylindrical workpart has a diameter = 2.5 in and a height = 4.0 in. It is upset forged to a
height = 2.75 in. Coefficient of friction at the die-work interface = 0.10. The work material has a flow
curve with strength coefficient = 25,000 lb/in2 and strain hardening exponent = 0.22. Determine the
plot of force vs. work height.
19.17 A cold heading operation is performed to produce the head on a steel nail. The strength
coefficient for this steel is 600 MPa, and the strain hardening exponent is 0.22. Coefficient of friction
at the die-work interface is 0.14. The wire stock out of which the nail is made is 5.00 mm in diameter.
The head is to have a diameter of 9.5 mm and a thickness of 1.6 mm. The final length of the nail is
120 mm. (a) What length of stock must project out of the die in order to provide sufficient volume of
material for this upsetting operation? (b) Compute the maximum force that the punch must apply to
form the head in this open-die operation.
19.18 Obtain a large common nail (flat head). Measure the head diameter and thickness, as well as the
diameter of the nail shank. (a) What stock length must project out of the die in order to provide
sufficient material to produce the nail? (b) Using appropriate values for strength coefficient and strain
hardening exponent for the metal out of which the nail is made (Table 3.4), compute the maximum
force in the heading operation to form the head.
19.19 A hot upset forging operation is performed in an open die. The initial size of the workpart is:
Do = 25 mm, and ho = 50 mm. The part is upset to a diameter = 50 mm. The work metal at this
elevated temperature yields at 85 MPa (n = 0). Coefficient of friction at the die-work interface = 0.40.
Determine (a) final height of the part, and (b) maximum force in the operation.
19.20 A hydraulic forging press is capable of exerting a maximum force = 1,000,000 N. A cylindrical
workpart is to be cold upset forged. The starting part has diameter = 30 mm and height = 30 mm. The
flow curve of the metal is defined by K = 400 MPa and n = 0.2. Determine the maximum reduction in
height to which the part can be compressed with this forging press, if the coefficient of friction = 0.1.
19.21 A part is designed to be hot forged in an impression die. The projected area of the part,
including flash, is 16 in2. After trimming, the part has a projected area of 10 in2. Part geometry is
complex. As heated the work material yields at 10,000 lb/in2, and has no tendency to strain harden. At
room temperature, the material yields at 25,000 lb/in2 Determine the maximum force required to
perform the forging operation.
19.22 A connecting rod is designed to be hot forged in an impression die. The projected area of the
part is 6,500 mm2. The design of the die will cause flash to form during forging, so that the area,
including flash, will be 9,000 mm2. The part geometry is considered to be complex. As heated the
work material yields at 75 MPa, and has no tendency to strain harden. Determine the maximum force
required to perform the operation.