Department of Mechanical Engineering,

Pulchowk campus, Institute of Engineering,

Tribhuvan University

MANUFACTURING AND PRODUCTION PROCESSES

Lecture 6: Bulk Deformation Process

Dr. Shree Raj Shakya

June 6, 2013
 Bulk Deformation Process
• Bulk deformation processes are those where the
thicknesses or cross sections are reduced or shapes are
significantly changed
• Involves stressing the metal work piece sufficiently to
cause it to plastically flow into the desired shape
• Since the volume of the material remains constant,
changes in one dimension require proportionate changes
in others
• Thus the enveloping surface area changes significantly,
usually increasing as the product lengthens or the shape
becomes more complex
• Initial work piece may be cylindrical bars and billets;
rectangular billets and slabs
• Process useful in adding geometric features and
sometimes improving mechanical properties, producing
near net shape or net shape products (No waste and No
machining)
 Bulk Deformation Process
• The bulk forming operations can be
performed in all of the temperature regimes
– Cold and Warm working
• when the shape change is less severe
• need to improve mechanical properties
• achieve good finish
– Hot working
• When massive deformation of large work parts is
involved
Bulk Deformation Process
Common processes
include: forging;
rolling; extrusion;
and drawing (wire,
rod, and tube)
 Forging
• Deformation process in which the work piece is
compressed between two dies, using either impact or
gradual pressure
• Around 5000 B.C.
• Used for manufacturing high strength components for
automotive, aerospace and other applications
– eg: engine crank shafts, connecting rods, gears, aircraft
structural components, jet engine turbine parts etc.
• Production of discrete parts with a set of dies
• some finishing operations usually required
• usually performed at elevated temperatures, but also
cold for smaller parts
• die and equipment costs are high
• moderate-to-high labor cost
• requires moderate-to-high operator skill
 Forging
• Different ways of forging process
• Working Temperature
– Hot or Warm and Cold Forging
• Impact or Gradual Pressure
– Forging Hammer and Forging Press
• Degree to which the flow of work metal is
constrained by the dies
– Open-die forging
– Impression die forging
– Flash-less forging
Forging
 Open – die Forging
• Simplest involves compression of a work part of cylindrical
cross section between two flat dies – Compression test
• Upsetting or upset forging reduces the height of the work
and increases its diameter
 Open – die Forging
Under ideal condition, homogenous deformation
occurs and the radial flow of the material is uniform
throughout its height

The strain “ε “ is given by

h0
ε = ln _____
hi

h0 = starting height of the work, mm

hi = the height at some intermediate point in the
process, mm
At the end, h = hf and true strain reaches maximum
 Open – die Forging
Deformation with friction

• In actual operation friction opposes the flow of work metal

at the die surfaces
• Barreling effect
• More pronounced on a hot work piece with cold dies
• due to faster heat transfer at and near the die surfaces
that cools the metal and increases its resistance to
deformation
• Significant as diameter to height ratio increases
 Open – die Forging
Forging force will be given by,

F = Kf Yf A
F = Forging force, N
A = cross – sectional area of the part, mm2
Yf = Flow stress corresponding to strain, MPa
Kf = Forging shape factor
Kf = 1 + (0.67 μ D)/h
μ = coefficient of friction
D = work piece diameter or other dimension representing
contact length with die surface, mm
h = work piece height, mm
The forging force, F, in an open-die forging operation on a
solid cylindrical work piece
 Open – die Forging Practices
• Important Industrial Process
• Shapes are simple – Shafts, disks and rings
• Steel Industry – large square cast ingot into a round
cross section
• Rough forms and require subsequent operations to
refine
• Favorable grain flow and metallurgical structure
• Types:
– Fullering
– Edging
– Cogging – Incremental forging
Open – die Forging Practices
Open – die Forging Practices
 Impression – Die Forging

• Performed with dies that contain the impression of

the desired shape of the part
• Flash is formed - cut away in a subsequent trimming
operation
• Flash cools quickly in hot forging increasing its
resistance to deformation
• Restricting flow causes the compression pressure to
increase forcing material to fill
Impression – Die Forging
 Impression – Die Forging
• Several forming steps involved in real process
 Impression – Die Forging
• The Forging Force, F, is give by

F = Kf Yf A

F = Maximum forging force in the operation, N

A = Projected area of the part including flash, mm2
Yf = flow stress of the material, Mpa
Kf = Forging shape factor
• Maximum force that will determine the required
capacity of the press or hammer
• Maximum force occurs when projected area is greatest
and friction is maximum
• Obtain final geometry and finished shape by machining
(remove flash)
 Impression – Die Forging

Part Shape Kf
Impression Die Forging
Simple shapes with flash 6.0
Complex shapes with flash 8.0
Very complex shapes with flash 10.0
Flash less forging
Coining (Top and bottom 6.0
surfaces)
Complex shapes 8.0
 Flash - less Forging

• In closed die forging the raw work piece is completely

contained within die cavity during compression and no
flash is formed
• Flash – less forging imposes requirements on process
control – Work volume must equal the space in the die
cavity within a very close tolerance
• Too large may damage the die or press
• Too small may not fill the cavity
• Lends best to part geometries that are usually simple and
symmetrical – Aluminum and Magnesium and their alloys
 Flash - less Forging
• Coining – Special application of closed – die forging
– Fine details in the die are impressed into the top and
bottom surfaces of the work part
– Little flow of metal yet high pressure required
– Making of coins
Advantages of forging compared to machining
– Higher production rates
– Conservation of metal
– Greater Strength
– Favorable grain flow
– Improvements have resulted thinner sections, complex
geometries, close tolerances and elimination of machining
allowances
– Precision Forging – Aluminum and Titanium
– Reduces Flash
– Near net shape or Net shape processes
Thank You