Forging

Forging is a metal working process that manipulates,

shapes, deforms, and compresses metal to achieve a
desired form, configuration, or appearance outlined by a
metal processing design or diagram. Depending on the type
of metal and the requirements of the design, the forging
process can be completed using either hot or cold forging
processes.

TYPES OF FORGING
1. HOT FORGING 2. COLD FORGING
Hot Forging: Hot forging requires the metal to be heated above its
recrystallization temperature. This can mean heating metals up to 2,300
degrees Fahrenheit.

Cold Forging: Cold forging typically refers to forging a metal at room

temperature, though any temperature below recrystallization is possible.
 Types of Forging Process:
1.Drop Hammer Forging 2. Press Forging 3. Upsett Forging

4. isothermal Forging 5. roll Forging 6. Roll Ring Forging

7. Multi Directional Forging

DROP FORGING
Drop forging gets its name from the process of dropping a hammer onto the
metal to mould it into the shape of the die. The die is the surface that comes
into contact with the metal.
 Types Of Drop Forging
1.Open Die Forging 2. Close Die Forging

Open Die Forging

When flat dies that have no precut profiles engage in
forging, the forge process is called open die forging (or
smith forging). The open design allows the metal to flow
everywhere except where it touches the die. it is useful
for short-run art smithing or for shaping ingots prior to
secondary shaping measures.

Close Die Forging

Closed die forging, sometimes called impression die forging,
employs the use of moulds. These moulds are attached to an
anvil while a hammer forces molten metal to flow into the
cavities of the die. Multiple strikes and/or die cavities are often
used when forging complex geometries.
 Forging hammers
Forging hammers are used to form the metal between two dies.
The first half of the die is attached to the anvil and the second
part to the hammer. The material is placed in the lower die and
then hammered with the upper one until the hot metal flows in
all directions, filling the die cavity.

Gravity Drop Hammer Forging

With a gravity drop hammer, the upper die is attached to a
ram and is raised by either a board, belt, or air . It is then
allowed to fall freely to strike the workpiece.The energy used to
deform the workpiece is obtained from the kinetic energy of the
moving ram and die.

The Board Drop Hammer

The board drop hammer has boards which are firmly attached to the ram and
are used to raise the ram to preset heights by means of revolving rolls pressed
against the boards. When the ram reaches the preset height, the pressure of
the rolls is released and the ram will either drop by gravity or the operator will
release the trip which causes a set of clamps to grip the boards, thus, holding
the ram at the top position. Since there is no downward force applied to the
ram, the force of the hammer is limited to the falling weight of the ram and the
stroke through which it travels. Standard sizes range from 1000 to 5000 pounds,
in increments of 500 pounds.
Air Lift Gravity Drop Hammer
The Air Lift Gravity Drop Hammer was developed
during the early 1800’s. It is similar to the board
hammer in that the forging force is derived from the
weight of the falling ram . the difference in that the
ram is raised by air pressure. A major improvement
in maintaining alignment of the ram (top) die with
the anvil (bottom) die was achieved with this design
in that the piston and rod could be maintained in the
same relative position to the ram. This allowed the
guiding surfaces to be fit more closely to the ram
itself, and improve dimensional variation
Specification

Size of 500 750 1000 1500 2000 2500 3000 4000

hammer (kg)

Weight of 550 800 1200 1800 2200 2700 3200 4100

tups (kg)

Max. weight 1 2 3 10 20 35 50 75
of job (kg)

Max no. of
blows per
min

Short stroke 135 120 100 75 75 55 55 55

Full stroke 90 80 70 50 50 35 30 25

Max. stroke
(mm)

Total height 17- 18- 19-8 21-2 22-3 22-6 24- 29

of machine 3 10 3
(ft.in)

Electric 30 40 50 75 100 125 150 200

Motor (H.P)
Power Drop Hammer Forging
In power drop hammer, the upper die is attached to ram and raised
either by steam /air, mechanically and drop by some external energy.
The energy used to deform the workpiece is obtained from the
kinetic energy of the moving ram and die.

Types of Power Drop Hammer Forging

1.The Air Power Drop Hammer 2. The Counterblow Hammer

Air Power Drop Hammer

Double acting hammer in which steam or air pressure is applied to both lift the
ram and also to drive it down with greater velocity than gravity alone. Such
hammers can attain ram speeds up to 350 inches per second, although for
stress and pressure design analysis a ram speed of 200 inches per second is
used.This hammer consists of a heavy anvil base which supports two frame
members (columns) that accurately guide the vertically powered ram. The
columns also support the cylinder in which the piston and piston rod is driven
to operate and power the ram. The lower surface of the ram carries the upper
die which contains the top half of the cavity or impression , that shapes the
forging. The lower die, which contains the remainder of the impression is
placed on anvil.
 Counterblow Hammer
Counterblow Hammers are not widely used in the U.S. but are used extensively
in Europe. The basic principle of counterblow hammer design is to drive the
upper ram downward using steam or air, while at the same time the lower ram
is accelerated upward by a steel band (which ties the top ram to the bottom), or
by a hydraulic coupling system (for larger hammers.) The lower ram is
approximately ten percent (10%) heavier than the upper ram which, therefore,
pulls the upper ram back to its starting position upon completion of the blow.

Counter blow Hammer

Calculation of unit capacity of Forging
Hammer:
E = 25 (3.5 or 6.3) K F total

E = strike energy require for forging (J)

K= steel type coefficient
F= Total deformation area of forging plan (include skin
and flash) (cm*2)
3.5 or 6.3 represent the productivity rate for higher
productivity,3.5 is used for final forging steps and low
productivity .
FORGING PRESS
A forging press is a process that uses a vertical ram to apply gradual
controlled pressure to a die holding a workpiece. The process is
similar to drop forging but uses slow pressure instead of a series of
blows. The slow movement of the ram penetrates deeper into the
workpiece so that the workpiece undergoes uniform plastic
deformation.
 Types of Forging Presses:
Mechanical Press
Mechanical presses are powered by a flywheel that stores energy from a
motor or engine. The released energy from the flywheel forces the ram down
onto the workpiece.

Parts of a Mechanical Forging Press

• Flywheel: The flywheel supplies the power to the forging press
and is driven by an engine or motor.
• Board: The board converts the rotary motion of the flywheel
into vertical motion.
• Ram: The ram is the connection between the board and upper
half of the die.
• Die: The die has two halves with one half connected to the ram
with the bottom half setting on the ram.
• Anvil: The anvil holds the bottom half of the die.

TYPES OF MECHANICAL PRESS :

1.C type mechanical or power press
2. H or pillar type mechanical press
Tabulation of C type Mechanical press
Tabulation of Pillar or H type Mechanical Press

Hydraulic Forging press:

Hydraulic presses create their force through hydraulic pressure from
a fluid using Pascal‘s Law. A small amount of force is applied to the
fluid, which moves a larger amount of fluid to create the force that
moves the ram to shape the workpiece. They operate slower than
other forging presses and have longer contact with the workpiece.
Parts of a Hydraulic Forging Press
• Safety Door: Safety door is a correction gate.
• Limit switch: The limit switch limits the amount of movement
past a certain point.
• Manual control Valve: The manual control valve allows for
control of the operation.
• Relief valve: The relief valve controls hydraulic pressure.
• Pressure gauge: The pressure gauge gives a reading of the
pressure.
• Hydraulic cylinder: The hydraulic cylinder applies
unidirectional stroke force.
• Oil tank: The oil tank stores the hydraulic fluid.
• Pressing Plate: The pressing plate applies pressure to the
workpiece.
• Bailing Compartment: The bailing compartment is where the
workpiece is placed to be shaped.
Types of hydraulic Press :

1.C type hydraulic press

2.H or Pillar type hydraulic press
 C type Hydraulic Press
Extendable working range, able to lengthen hydraulic stroke
using three sided space with max retracibility 260mm to
800mm . able to preset working pressure and heat abstractor
device.
 H type Hydraulic Press
It is applicable for pressing plastic material like
powder product forming , plastic powder product
forming, sheet drawing , transverse pressing, bending,
hot extrusion.

Calculation of capacity of Power

press :
T = P x Th x C
T = Pressure required in tons
P = Perimeter of blank in inches
Th = Thickness of material
C = Constant
Constant = The material shear strength/2000 pounds
Tabulation of Manual and C type Hydraulic press

Tabulation of H Frame Hydraulic Press

HEAT TREATMENT PROCESS

Heat treatment is a hot metal working process referred to
material under solid state, by means of heating, heat
preservation and cooling, to get the expected organization and
properties.

TYPES OF HEAT TREATMENT PROCESS:

Annealing Process : Annealing is a heat treatment process

that heating drop forgings to above AC3 20 to 40℃, heating
preservation a while, then cooling down with furnace to below
500℃ in the air. Normalizing is a technique used to provide
uniformity in grain size and composition throughout an alloy.

Normalizing Process: Normalizing is heating steel forgings to

temperature above Ac3 or Accm+30℃ to 50℃, then cooling
down slightly faster than annealing after heating preservation.
For low & medium carbon steel and low alloy steel drop
forgings, we could also use it as the last heat treatment
process.

Quenching Process: Quenching is to heat parts above Ac3 or

Ac1, and heat preservation for a while, then fast cooling in
water, oil or air. The destination of quenching is to obtain high
hardness martensitic structure, thus to improve wear resistance
and corrosion resistance. Quenching fits for carbon steel and
alloy steel drop forgings with carbon content above 3%.
Hardening process: Hardening is a metallurgical
metalworking process used to increase the
hardness of a metal. The hardness of a metal is
directly proportional to the uniaxial yield stress at
the location of the imposed strain.

Tempering Process: Tempering is a process of heat treating,

which is used to increase the toughness of iron-based alloys.
Tempering is usually performed after hardening, to reduce
some of the excess hardness, and is done by heating the
metal to some temperature below the critical point for a
certain period of time, then allowing it to cool in still air. The
exact temperature determines the amount of hardness
removed, and depends on both the specific composition of
the alloy and on the desired properties in the finished
product.
 Type of
heat
treatment
process
Annealing Complete Isothermal Spherical Recrystalization Diffusion
Annealing Annealing annealing Annealing Annealing

Normalizing
Hardening Case Induction
hardening Hardening
Tempering Differential Austempering Martempering Black Tempering White
Tempering
Temp 710*C Temp b/w 150 Tempering
to 920 *C to 300 *C Temp Above Temp b/w
950*C` High then
1000*C