Subject Name: Manufacturing Process

Subject Code: ME-3004

Semester: 3rd
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Notes of Unit-3
ME-3004 Manufacturing Process, Mechanical Engineering, III-Semester
Forging: types of forging operations Theory and application of forging processes description; drop and
horizontal forging machines.
Forging
Forging is manufacturing process where metal is pressed, pounded or squeezed under great pressure into high
strength parts known as forgings.

The forging process

• Heated metal to be shaped is placed on a mold. Pressure is applied to the metal with the help of a press
or hammer and due to this impact the malleable metal conforms to the die cavity shape.
• Extreme pressure is produced when the die halves are closed. The seam of the die as well as punch acts
as a relief valve. Once the metal object is shaped, flashing is removed.
• Use of a proper lubricant during the process helps to prevent sticking of the workpiece with the die. It also
acts as a thermal insulator and helps the wear and tear on the die.
• The process is used on metals with good ductility such as copper, aluminum, nickel, steel, and magnesium.
Minimizing size, material volume, and complexity of the design can reduce cost.

Example parts: Connecting rods, crankshafts, wrenches, hooks etc.

Advantages of Forging

• The forgings are consistent in shape and do not have any voids, porosity, inclusions, or defects.
• This is especially helpful in later finishing and coating operations as surface preparation is minimized.
• Parts that are produced by this method have high strength to weight ratio and therefore used in the design
of the aircraft frames.
• It offers low cost for moderate to long runs.

Classification of forging processes

• By equipment

- Hammer or drop forging

- Press forging

• By process
- Open-die forging
- Closed-die forging

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Different types of Forging processes

• Open Die Forgings or Hand forgings

In this process the forgings are made with the help of repeated blows in an open die. Here the operator
a ipulates the o k pie e i the die du i g the lo p o ess, si ila to the t aditio al a ufa tu i g
process used by a blacksmith.
Open-die forging is carried out between flat dies or dies of very simple shape.
The process is used for mostly large objects or when the number of parts produced is small.
Open-die forging is often used to preform the workpiece for closed-die forging.

• Impression Die Forgings or Precision Forgings

These forgings are the refined form of blocker forgings. The finished metal part much more identical to
the die impression.

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• Upset Forgings
These forgings increase the cross-section by reducing the length of the metal. The process is used to
make heads on valves, bolts and fasteners, and other similar parts.

Forging Design Guidelines

• Avoid undercuts.

• Recommended external draft: 6 degrees (96).

• Recommended internal draft: 8-10 degrees (98-100).
• Provide generous fillet and corner radii to aid material flow.
• Provide support webs and ribs.

A Forged metal can result in the following-

• Increase length, decrease cross-section, called drawing out the metal.
• Decrease length, increase cross-section, called upsetting the metal
• Change length, change cross-section, by squeezing in closed impression dies. This results in favorable
grain flow for strong parts
Forging Operations

Edging is used to shape the ends of the bars and to gather metal. The metal flow is confined in the
horizontal direction but it is free to flow laterally to fill the die.

Drawing is used to reduce the cross-sectional area of the workpiece with concurrent increase in length.

Piercing and punching are used to produce holes in metals.

Fullering is used to reduce the cross-sectional area of a portion of the stock. The metal flow is outward
and away from the centre of the fuller. i.e., forging of connecting rod for an internal combustion engine.

Swaging is used to produce a bar with a smaller diameter (using concave dies).
• S agi g is a spe ial t pe of fo gi g i hi h etal is fo ed a su essio of apid ha e lo s
• S agi g p o ides a edu ed ou d oss section suitable for tapping, threading, upsetting or other
subsequent forming and machining operations.

Cold Forging is a cold working process where the material is squeezed into a die and the finished parts assume
the shape of the die. This process is also known as Cold Heading.

Functions of flash
The flash serves two purposes:
• A ts as a safet alue fo e ess etal.
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• Builds up high p essu e to e su e that the etal fills all e esses of the die a it .

It is necessary to achieve complete filling of the forging cavity without generating excessive pressures against
the die that may cause it to fracture.

Bar stock or wire stock is fed into a die and is squeezed into the closed die. The resultant part is a nail, a bolt or a screw
with the head.

A subsequent cold heading operation forms other features on the head such as knurls or slots for screw drivers etc. the
shaping rod stock by forming the head as in rivets, bolts, nails and other fasteners.

This process can be highly automated and parts can be made economically.

There are four basic types of forging machines

There are two basic types of forging hammers used;

• Boa d ha e
• Po e ha e
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There are two basic types of forging presses available;

• Me ha i al p esses
• H d auli presses

Board hammer –forging hammer

• The uppe die a d a a e aised f i tio olls g ippi g the oa d.

• Afte eleasi g the oa d, the a falls u de g a it to p odu e the lo e e g .
• The ha e a st ike et ee 60-150 blows per minute depending on size and capacity.
• The oa d ha e is a e e g est i ted a hi e. The lo e e g supplied e ual the pote tial e e g due
to the weight and the height of the fall.

Potential energy = mgh

• This e e g ill e deli e ed to the etal workpiece to produce plastic deformation.

Power hammer
• Po e ha e p o ides g eate apa it , i hi h the a is a ele ated o the do st oke stea o ai
pressure in addition to gravity.
• Stea o ai p essu e is also used to aise the a o the upstroke.
• The total e e g supplied to the lo i a po e d op ha e is gi e -

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W = ½ mv2 + pAH = (mg + pA)H

Where,
m = mass
v = velocity of ram at start of deformation
g = acceleration of gravity
p = air or steam pressure acting on ram cylinder on downstroke
A = area of ram cylinder
H = height of the ram drop

***

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