Lecture 3 Syllabus Unit 3 - Mar 23

B.
Tech Final Year 8th Semester
Forging Technology
College of Engineering, Pune
Dr. Madhu Ranjan, Emeritus Professor February 2019

Syllabus Unit 3
• Principal forging processes
– Upset Forging
– Cogging Operation
– Fullering
– Edging
– Coining
– Heading
– Drawing Out
– Ring Rolling Forging Process
– Swaging Machines
– Core Forging
– Punching and Drifting
– Extrusion
• Types of Forging Equipment
– Rotary Forging Machines
– Cross Rolling Forging
– Shear Forming Machines
– Furnaces
Principal Forging Operations
• Upset Forging and Barreling
• Upset forging increases the diameter of the workpiece by
compressing its length
a) Solid cylindrical billet upset between 2 flat dies

b) Uniform deformation of the billet without friction
c) Deformation with friction
• Upset Forging
• Cogging Operation
• ‘Cogging’ is the successive deformation of a bar along its length
• It is commonly used to work a piece of ‘raw material’ to the proper
thickness
• Once proper thickness is achieved, the proper width is achieved
via ‘edging’
a) Cogging operation on a rectangular bar

b) Reducing the dia of a bar in an open-die forging
c) Reducing thickness of a ring in an open-die forging
• Fullering
a) A ‘fuller’ is a tool used to form metal when it is hot
b) The ‘fuller’ has a rounded nose, which spreads the metal
more efficiently than the flat face of the hammer
c) ‘Fuller’ is used primarily to spread the metal
d) The fuller is placed on the stock, and either the fuller or the
stock is struck with a hammer
e) The process leaves ridges on the stock, which may then be
flattened out later with the hammer or other tools
• Edging
• Edging is the process of concentrating material using a concave
open-die
• It is called ‘edging’ because it is usually carried out on the ends
of the workpiece
• This process prepares the workpiece for further forging
operation
Types of Forging Operations
• Coining Process
• Coining is a closed die forging process, in which pressure is

applied on the surface of the forging in order to obtain closer
tolerances, smoother surfaces and eliminate draft
• Heading Process
• Heading is a metalworking process which incorporates
forging, extruding and upsetting operation
• It is often performed in cold state
• Produces near-net-shape
• Drawing Out
• Ring Rolling Forging
• The ring-rolling process starts with a circular pre-form of
metal that has been previously upset and pierced to form a
hollow doughnut
• The doughnut is heated above the recrystallization
temperature and placed over the idler or mandrel roll
• The idler roll then moves under pressure towards a drive roll
that continuously rotates to reduce the wall thickness,
thereby increasing the diameter of the resulting ring
• Ring Rolling Forging Process Steps
1. The process usually begins with upsetting of the starting stock on
flat dies
2. Next, piercing, which involves forcing a punch into the hot upset
stock, causing metal to be displaced radially
3. Next, shearing, to remove the small punch out
4. Producing a completed hole through the stock, which is now ready

for ring rolling. The stock is called a ‘preform’
5. The preform is slipped over the ID roll
6. A side view of the ring mill and preform work piece , which
squeezes it against the OD roll, which imparts rotary action
• Swaging
• Swaging is a forging process in which dimensions of an item
are altered using dies into which the item is forced
• The die applies compressive forces by hammering radially
• It is usually a cold working process, but some times hot-
working is also done
a) Swaging of tubes without a

mandrel
a) Swaging with a mandrel

• Swaging
• Swaging is used to produce a bar with

a smaller diameter (using concave
dies).
• Swaging is a special type of forging in
which metal is formed by a
succession of rapid hammer blows Swaging at the ends
• Swaging provides a reduced round ready for next forming
cross section suitable for tapping, operations
threading, upsetting or other
subsequent forming and machining
operations.
• Swaging
• Core Forging
• Punching and Drifting Operation
• Punching operation is used to produce or enlarge a hole in
the work piece by hammering a tool called ‘Punch’. The hole
may also be ‘blind’
• Drafting operation is to cut and slit in the work piece. The
tool used is called ‘draft’, which has a very small cutting angle
with sharp edge
• Some times a circular drift is also used to enlarge the hole to
the required dimension
• Both the operations can be carried out at room temperature
or at high temperature
• Punching and Drifting Operation
• Extrusion Process
• Extrusion is the process by which a

block/billet of metal is reduced in cross
section by forcing it to flow through a die
orifice under high pressure
• In general, extrusion is used to produce
cylindrical bars or hollow tubes or for the
starting stock for drawn rod, cold
extrusion or forged products.
• Most metals are hot extruded due to
large amount of forces required in
extrusion.
• Complex shape can be extruded from the
more readily extrudable metals such as
aluminum.
• Extrusion Forging
• Extrusion Products
Typical parts produced by extrusion
• trim parts used in automotive and
construction applications,
• window frame members,
• railings, aircraft structural parts.
Example:
• Al-extrusions are used in commercial and
domestic buildings for window and door
frame systems, prefabricated
houses/building structures, roofing and
exterior cladding, curtain walling, shop
fronts, etc.
• Extrusions are also used in transport for
airframes, road and rail vehicles and in
marine applications
• Classification of Extrusion Process
There are several ways to classify metal extrusion
processes;
• By direction
• Direct / Indirect extrusion
• Forward / backward extrusion
• By operating temperature
• Hot / cold extrusion
• By equipment
• Horizontal and vertical extrusion
• Extrusion Process by Direction: Direct and Indirect
• The metal billet is placed in a container and
driven through the die by the ram.
• The dummy block or pressure plate is
placed at the end of the ram in contact with
the billet.
• Friction is at the die and container wall -
requires higher pressure than indirect
extrusion
--------------------------------------------------------------
• The hollow ram containing the die is kept
stationary and the container with the billet
is caused to move.
• Friction at the die only (no relative
movement at the container wall) requires
roughly constant pressure.
• Hollow ram limits the applied load.
• Extrusion Process by Direction: Forward and Backward
• Metal is forced to flow in the same

direction as the punch.
• The punch closely fits the die cavity to

prevent backward flow of the material
-----------------------------------------------------------
• Metal is forced to flow in the direction
opposite to the punch movement.
• Metal can also be forced to flow into

recesses in the punch
• Cold Extrusion
• Cold extrusion is the process done at room
temperature or slightly elevated temperatures.
• This process can be used for most materials-
subject to designing robust enough tooling that
can withstand the stresses created by extrusion.
• Metals that can be extruded: Pb, Sn, Al-alloys,
Cu, Ti, Mo, Va, steel.
• Cold extruded parts: collapsible tubes,
aluminum cans, cylinders, gear blanks.
• Advantages
• No oxidation takes place.
• Good mechanical properties due to severe
cold working as long as the temperatures
created are below the recrystallization
temperature.
• Good surface finish with the use of proper
lubricants.
• Hot Extrusion
• Hot extrusion is done at fairly high
temperatures (~ 50 to 75 % of the MP of
the metal). The pressures can range
from 35-700 MPa
• The most commonly used extrusion
process is the hot-direct-process. The
cross-sectional shape of the extrusion is
defined by the shape of the die.
• Due to the high temperatures and
pressures and its detrimental effect on
the die life as well as other components,
good lubrication is necessary. Oil and
graphite work at lower temperatures,
whereas at higher temperatures glass
powder is used.
Types of Forging Equipment
• Drop and Counter Blow Hammers
• For Drop Hammers the necessary force and energy are
supplied by a falling weight or Ram, usually assisted by
pressurized air or steam
• Production Drop-Hammers range in size > 500 pounds
• The largest known single action drop-hammer is a 50,000
pounds steam hammer
• Ram velocities of Drop-Hammers are around 150-220 in/sec,
depending upon the stroke length and availability of
assistance, such as air/steam
• During forging the Ram strikes the workpiece with repeated
blows, thus shapes the metal in a step-wise fashion
• Drop hammers are equipped with an Anvil 10-20 times
heavier than the Ram
www.dtic.mil/dtic/tr/fulltext/u2/460465.pdf
Relies only on
gravity
• Drop and Counter Blow Hammers
• The operation of Counter Blow Hammers is quite similar to
the Drop Hammers, except that the two rams are activated
simultaneously in opposite directions.
• They strike repeated blows at a mid way point and develop
combined velocities about 1-1/2 the normal hammer
velocities
• The equalized dynamic forces of the opposite moving rams
eliminate the need for the heavy bases characteristics of the
single-action drop-hammers
• Drop and Counter Blow Hammers (Images)
a) Drop Hammer
b) Double Acting Hammer
c) Counter-blow hammer
• Hydraulic Presses
• Operated by large pistons driven by high pressure hydraulic
or hydro-pneumatic systems
• They are usually slow moving (up to 2 inches per second)
under pressure
• Two basic types of hydraulic presses used for forging
• Direct Drive Hydraulic presses. These presses operate with
hydraulic fluids (oil or water) pressurized directly by high
pressure pumps
• Hydro-pneumatic presses. These presses operate with
hydraulic fluids supplied from accumulators which are in
turn pressurized by high-pressure pumps. The larger
presses are of this type
Hydraulic press
• Operate at a constant speed
• They are load limited (press stops if the
load required exceeds its capacity)
• Takes longer than other types of forging
machines 􀃆 workpiece may cool
• Capacity
○ 125MN for open forging
○ 450 MN – 730 MN (differs in
different countries) closed-die
forging
• Compared to mechanical presses
○ Higher initial cost, slower
○ Require less maintenance
• Multiple Ram Presses
• This offers advantages not available in single action press-
forging equipment or in drop-hammer equipment
• A typical multi-ram hydraulic forging press can be used to
forge hollow parts in one pressing
• Mechanical Presses
• Mechanical presses differ from Drop-Hammer and Hydraulic
Presses in that they force two working surfaces together by
offset cams, cranks, and other rigidly connected mechanical
systems
• The strokes of mechanical presses are shorter than those of
either hammers or hydraulic presses
• Mechanical presses are often favored for low profile forgings
• They have accurately controlled strokes, therefore provide
closer tolerances
• Ram speeds of 1 – 10 inches per second
Mechanical press
• High production rates
• Require less operating skills
than other forging processes
• 2.7 MN – 107 MN
• Knuckle-joint mechanical
press
○ Very high forces can be applied
with this design
 Screw Press
• Forging load is transmitted
through a vertical screw
• Used for both open- and
closed-die forging Operations
b) Mechanical press with an eccentric drive; the eccentric shaft can be replaced
by a crankshaft to give the up-and-down motion to the ram(c) Knuckle-joint press.
(d) Screw press.
• Impactors
• Impactors consist of opposed hammers that operate on the
same principle as the Counter-blow hammers, except that
the Rams operate horizontally
• Designed specifically for high quantity low-profile forgings
• The rams are said to strike at speeds about equal to that of
the hammers
• Since it minimizes die-chilling, impactors are useful for
producing forgings with thinner sections
• High Energy Rate Machines (HERM)
• It is based on same principle as Die-hammer and Impactors,
• Provides greater energies for a given Ram weight by applying
ram velocities on the order of 2 – 10 times that of drop-
hammers
• Since the die contact times are small, forgings with thin
sections can be produced
• Owing to high strain rates, the metal temperature may
actually increase
• Ring Rolling Forging Mills
• It is based on same principle as horizontal bar rolling mills,
except that the rolling process starts with a thick-wall, ring
shaped blank instead of a billet
• By continuously reducing the wall thickness, the
circumference of the ring is increased
• The ring shaped blanks are die-forged in presses or hammers
• It is a big advantage that the circular shape does not need any
welding
• Swaging Machines
• The most common type of swaging machine consists of a
power driven ring that revolves at a high speed causing rollers
to engage cam surfaces and force the segmented dies to
deliver hammer like blows on the work at high frequencies
• The machines are useful for reducing thickness of rods
without resorting to expensive rolling process
• They can produce both straight and tapered cylindrical
sections
• Rotary Forging Machines
• It operates on a principle similar to that of a swaging
machine, but are more versatile
• It can be used to work bar and tubing into a variety of round
shapes having varying dia and tapers along the axis
• Used for short runs
• The toolings are least expensive
• Rotary Forging Machines
Examples of die motion in rotary forging.

(a) Upper die has both translational and rotational motion, while lower die rotates.
(b) Upper die has translational, rotational, and orbital (rocking) motion; lower die is
stationary.
(c) Upper die has orbital (rocking) motion only; lower die has translational motion.
• Shear Forming Machines
• It is also known as hydro-spinning, spin-forging, shear-
spinning, flow-turning etc.
• It combines spinning with a ring-rolling process
• Flat metal blanks are reduced in thickness between the rolls
and the mandrel, and the shape is frequently changed to
asymmetrical shapes, such as cones, cylinders and hemi-
spheres
• Although this operation is not considered as forging, it is
frequently tied in closely with other forging operations in the
production of such shapes
Shear Forming Schematic
1. A sheet metal blank is
placed between the
mandrel and the chuck of
the spinning machine. The
mandrel has the interior
shape of the desired final
component.
2. A roller makes the sheet
metal wrap the mandrel
so that it takes its shape.
As can be seen, S1 which is
the initial wall thickness of
the workpiece is reduced
to S0.
• Shear Forming Schematic
• Upset Forging
• The behavior of metals during forging is influenced by the time
necessary to complete the plastic shaping
• Thus it is important to recognize that the basic difference
between the types of equipment lies in their forging-velocities
(or rate of deformation)
• Forging hammers, for instance, deforms metals at rate of
deformation on the order of 100 times faster than hydraulic presses
www.dtic.mil/dtic/tr/fulltext/u2/460465.pdf
Heating Devices / Furnaces for Hot Forging
• Induction Furnace
• Induction heating is the process of heating an electrically conducting
object (usually a metal) by electro-magnetic induction, through heat
generated in the object by eddy currents
Heating Devices / Furnaces for Hot Forging
• Furnace : Fuel Fired or Electrical resistance heating
• Schematic of a Manufacturing System for hot-forging
Auxiliaries in Automatic Forging Press
Auxiliaries in Automatic Forging Press
Safety / Protection in Forging Press
Lubrication System
• Single line progressive automatic lubrication system
Lubrication System
• Dual line parallel automatic lubrication system
?

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B.

Tech Final Year 8th Semester

College of Engineering, Pune

Dr. Madhu Ranjan, Emeritus Professor February 2019

a) Solid cylindrical billet upset between 2 flat dies

a) Cogging operation on a rectangular bar

• Coining is a closed die forging process, in which pressure is

3. Next, shearing, to remove the small punch out

4. Producing a completed hole through the stock, which is now ready

5. The preform is slipped over the ID roll

a) Swaging of tubes without a

a) Swaging with a mandrel

• Swaging is used to produce a bar with

• Extrusion is the process by which a

• Metal is forced to flow in the same

• The punch closely fits the die cavity to

• Metal can also be forced to flow into

Examples of die motion in rotary forging.

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