Forging

INTRODUCTION
• Forging is process of plastically
deforming metal or alloy to a
specific shape by a compressive
force exerted at elevated
temperature by some external
agency like hammer, press, rolls,
dies or by an upsetting machine.
• Bolts, nuts, nails, cams, crank
shafts, connecting rods, axles etc.
are produced by forging.
 CLASSIFICATION OF FORGING
• On the basis of process : Forging
1. Open die Forging Proces
2. Closed die Forging s
Open die Closed die
• On the basis of equipment : Forging Forging

1. Drop Forging Hand Power Drop Press Machine

Forging Forging Forging Forging Forging
2. Power (Hammer & press) Forging
3. Hand Forging Power
Hammer
Press
Forging
4. Machine Forging
OPEN DIE FORGING
• This process also known as smiths die
forging or flat die forging.
• The operation is carried out between two flat
dies of very simple shape generally b/w the
bottom surface of hammer & top surface of
anvil..
• The workpiece reduces their height/plastically
deform by compressing it.
• The process is used for mostly large objects or
when the number of parts produced is small &
to perform the work-piece for closed-die
forging.
• Tooling is simple, inexpensive and allows the
production of a large variety of shapes.
 CLOSED/IMPRESSION DIE FORGING
• This process is also called impression die
forging.
• In this metal is deformed under high pressure
between two dies (called tooling) or in a
closed cavity that contain a profile of the
desired part.
• Closed die forging are commonly use where
mass production of identical & more complex
shapes of greater accuracy are required.
• The process provide precision forging with
close dimensional tolerance.
• Normally used for smaller components.
• Closed dies are expensive.
 DROP FORGING
• It is also called as stamping. It consists of special type of
hammer known as drop hammer or drop stamp.
• Perfectly made steel dies are used for forging.
• The top part of the die is raised by mechanical links to a
certain height.
• The heated metal placed accurately in the bottom part of
the die.
• The top part of the die is then allowed to fall suddenly.
• This gives a high blow and completes the workpiece in a
single operation.
 HAMMER FORGING
• Machine which is work by blow or impact to perform forging process is known as hammer forging.
• Power hammer provides greater • The upper die and ram are raised by
capacity, in which the ram is friction rolls gripping the board.
accelerated on the down stroke
by steam or air pressure in • After releasing the board, the ram falls
addition to gravity. under gravity to produce the blow
energy.
• Steam or air pressure is also • The hammer can strike between 60-
used to raise the ram on the
upstroke. 150 blows per minute depending on
size and capacity.
FORGING ANALYSIS
Example A block of lead 25 mm x 25 mm x 150 mm is pressed between flat dies to a size 6.25 mm x 100 mm x
150 mm. If the uniaxial flow stress is (Jo = 6.9 MPa and /l = 0.25 determine the pressure distribution over the 100
mm dimension and the total forging load.
 Close Die Forging
The description of the closed-die forging process previous section has emphasized the important role of the flash in
controlling die fill and in creating high forging loads.
Usually the deformation in closed-die forging is very complex and the design of the intermediate steps to make a final
precision part requires consider able experience and skill.
Overall success of the forging operation requires an understanding of the flow stress of the material, the frictional
conditions, and the flow of the material in order to develop the optimum geometry for the dies.

The design of a part for production by closed-die forging involves the prediction of:

1. Workpiece volume and weight

2. Number of preforming steps and their configuration
3. Flash dimensions in preforming arid finishing dies
4. The load and energy requirements for each forging operation

Metal flows away from the neutral surface in a direction perpendicular to the die motion. In designing a preform it is usual
practice to take key cross sections through the forging and design the preform on the basis of the metal flow. Some general
considerations are:
1. The area at each cross section along the length must equal the area in the finished cross section plus the flash.
2. All concave radii on the preform should be larger than the radii on the final forged part.
3. The cross section of the preform should be higher and narrower than the final cross section, so as to accentuate
upsetting flow and minimize extrusion flow.
 POWDER METALLURGY FORGING

A new and rapidly growing area is the production of closed-die forgings from powder metallurgy
preforms (P/M forging). The use of sintered P/M preforms rather than bar stock as the workpiece
offers advantages of improved material utilization through reduction or elimination of machining,
forming to final size in one forging stroke, uniformity of structure and reduced directionality of
proper ties relative to conventionally forged parts.

Working with a sintered powdered metal preform introduces new aspects to the mechanics and
metallurgy of plastic deformation. Because it contains a dispersion of interconnected voids, the
deformation of a P/M preform is much different from a conventional fully dense workpiece. With a
P/M preform the workpiece decreases in volume during plastic deformation as the porosity is
closed up and eliminated by the act of plastic deformation.
 Basic plasticity mechanics of a porous powder metallurgy preform
The relationship between densification and plastic deformation is achieved through
relating the plastic Poisson ratio ν to the fraction of theoretical density ρ/ρt·
ν = 0.5 (ρ/ρt)2 ----------------------------- eqn (16.24)