2 PRODUCTION ENGINEERING II ABPURI 10 CHAPTER I: FORGING TRODUCTH Jin metal forming, force is applied on the vork piece Such thot tht material is deforsned and the desised shape 2nd size of fle work piece is oblained fom a metal stock Desirable properties a metal founisig are low yield strength and high ductility. These properties are affected’ by temperature. Ductity inereas®s and yield Datel spe during upseting. This is kagwa as barrelling [Fig (c)] The processfequizes a higles load aad the fexra enefsy eqhiced ta that oPehomozeneows deformation i fermed 2: cedaadant work Barrelling ic munimigeddby asin an ¢ffective Imbricamt (b) Cogging (or Drawing out) is the operation in_yhich the metal getsycloageted with 9 reduction 19 cross seciloraf area. The thickness ofs bare reduced by taenies Of successive RMBing tepe'atsperificinervafe along ‘the leagth of the workpiece.ME 602 PRODUCTION ENGINEERING II ABPURI 11 (© Fullering: In fullering. open die with convex surfaces are used to deform the work piece. The cross sectional area reduces as the metal flovrs ont to both sides. (@) Edging: In edging, open die with concave surfaces is used. The cross sectional area increases as the metal flows into anazea from both sides, Friction forces, (b) © IMPRESSION-DIF FORGING Jn igpession-e forzing (also kmown/ 9 stamping) the workpiece 2eqhiresth shape of che die Cai while being forzed berweea two shaped dies. Excess metal is squeezed out around the periphery of the cavity te form “fash. Oa completion, the fash is timmed off with the help of miming dies. Most impzession die-sets contain several cavities. The work matesial is given final desired shape in more tha one stage. Cavaties are made ia such 2 way to cause the metal to flow in desired éixecion imparting the desired structare to the componeat cS) | a a a ae on operations such as powder metallurgy. c) Casting or d) using a preformed blank from forging operation. The umtation of the process 1s that st cannot produce close tolerance work. Machining or other finishing operation 1s often required to achieve the desired dimensional accuracy. Preshaping/ Preforming: Ino properly pre-shaped workpiece. material should not dlow easily into the dash, {gain flow pattem should be favouFable fore products" Sengtatdhr lability, and Giiag ae hie Warkpiece As! interfaces soul be minimized in cxder wo tediuce die wear Cogglng, fullering, edging, blocking ete are such reforming pfocesses in which materiahis distibuced into othes/segion|af the blank, In blocking’ the part formed into a ough shape using blacker dies The final operation is done using impfession dies than gives the foxging its final shape, CLOSED-DIE FORGING (Or FEASHTESS FORGING) Jn true closed-die forging. Mash does not form and the workpiece completely fills the die cavity. Proper contol ‘of the volume of material vs. die cavity is essential ia order to produce a forging of desised shape and dimension. Tndersized blanks prevent the complete filling of the die cavity. The same die is applied to impression die forging with flash generation_At the endl of operation, the die surfaces around the periphery of the work may be ‘in contact with each other. PRECISION FORGING. Te It is badloally a achless forging operatién in whiclt special baneh and mare complexdies with a Very high aécuracy are! used. Tt 4s also -knownea® slear-net-shape matuficruring Aluminium and magnesium alloys are particularly suitable as work ‘material a¢ the forging loads and temperanye requited ase selativaly low Otherwise, the process is similar to closed-die forging and coining Die [Lower] Die punci 1. Start of stoke 2.End cf stokeME 602 PRODUCTION ENGINEERING III ABPURI 12 RIOUS FORGING OPERATION 2) Coining Iris a closed-die foruing processiused in the mimting~ofyeoinsy medallions and jewellery. The pressure wsed is as high as 5-6 times Unpar te flow fess of the work material: Eubnicantscan|not beslS€ 3 pussy they da be tapped in die cayines|and finer decals Preventing | Dihoter eprogaction of details of the die surfxces, ie ye i aki Neve » ee Lowe die This a process of indenting the surface of a workpiece upto a certain depth With 2 pimel in order to produce a cavity or an impression. Piercing force depends on c1oss-sectional area ‘nd the ip geometry of the puach, stenath ofthe material and magnitude of fiction at the sliding interfaces, © Bubbing It consigs of presing « hagdeaed punch with a,tip geometry into the swrfice of a block of, metal produce 2 cavity mac thallower than thet of Piexciag, Hubbing! force ean be estimated a, F = 3-Uhienste Tensile Stress Aa the projected ate of te impression. 4) Heading (Or Upset Forging) It # an upsettidg operation peetormed ea the end oF round rod or Wire in ofder to inatease the cross seetion "Products are-nails ot heads, sefewsenivets ete Kiekout gi Dis Blank Hoad tormod npench Punch SS re eater ©) Swaging Rotary forging or Rotary Swaging) This processis abo inown a6 roms Swasing orvadiabswacing. 1 ti process. the diameter of a od os a tube 15 seduced by foreme st sto a confining die. set of reciprocation dies (is-and-out type) or stay dies provides radial smpact forces to cause the metal to How inward aad acquite the form ofthe die cavity. When the infernal diameter is reduced fa with the merease of thickness of the tube using swaging. itis called tube swaging. With the use of mandrel te thikness ofthe mibe a eect: are obtained using suitable mandrels. The process is als9 well-suited in drawing operations prourfel Tube Die Mandel It inwolges heated bar being fed into A pais of cylindsical rollé that have >}. en the shape of the required component cut into their surfaces. Upon feeding of stock. the rolls are sotated for half a revolution. at the end of which the forged part is ejected. The rolls may be semi-cisGilar, grooved or BRBBIEE This is also ws ARRAS. FRRRctes SFOS 9) Orbleal Forging Upper die moves wile compreSSiagthe work: alowigau?@fbial pot and forms the past geyBinenialiy. Operation is quiet parts are formed within 10to 20 cycles ofthe orbiting di aME 602 PRODUCTION ENGINEERING II ABPURI 13 by Incremental Forging In this process. a tool forges.a.blank into a shape.in several smallsieps. Similor.to cogging where. the die penetrates the blank to different depts along the surface {) Isothermal Forging Rnowal ay hatedie forging process whee it heats the die to the same temperature as workyiiece, Complex parts swith good dimensional accuracy ean be produced, DIE MATERIALS Requirements for die materials are (a) strength and toughness at elevated temperatures, (b) hardensbility and abiliry to harden uniformly. (c) resistance to mechanical and thermal shock and (4) weer resistance During the manufacture of a hot forged part, the forging die is usually prelieated before the operation begins. reheating forging die reduces thermal cycling that can cause cracks in the die. Metal foraine die are hardened and tempeted. Forging die iliiensiohs must accptnt for Shrinkage of the Work as well a8, cxtra\ material allowaules for the finishing ofthe part The abrasive wear in hot forging operations as duc t@ the scale on the work stock, Much of the scale ¢amibe semoved from the blank immediately after heating in ube furnace, prior 10 the férging ofthe par. Adequate lubsieation can also creacly mitigate wear. Sometime: a forging die may be assembled using different die sectious. These sections, called die inserts. are manufactured separately and may heat diflereut materials. Complesctarities can be produced easily swithldieiserts: alse differeut sections of the forging die can be individually replaced. Some factors 19 consider when determining the material composition of a forging die are, ‘ype of operation, umber of die forgings, size of forged pats, complexity of forged parts, type of machinery to be used, ‘temperature thot the metal will be forged at, and the cost of materials. Forging die are made from tool steels that, depending upon process entenia, are alloyed with vanons levels of one or more of these materials. chromyum. ‘molybdendaa, vanadim, and aiekel Die blocks are cast fim the alley, forged, then machitied. ad finished. LUBRICATION © Gheatlydafljences friction and wear © Affects the forces required, die lif aud material flows into the die cavities, Frictioual fortes within the could, between the work and the surfaces of the die cavity. have 2 large faflueace ‘over the flow of material in a metal forging operation. Lubricants are used in industrial metal forging production in order to lower frictional forces, and enact a smoother flow of metal through the mould. Tn addition. they are ‘used to slow the cooling of the work and seduce temperanure gradients, ia hot forging manufacture, serving 26 2 ‘thermal barrier berweea the metal work and the die, Lubricants also help keep the metal and die surfaces from sticking togetzer and assist in theremovahof the metabforzing:irom thejdie= Conmowrlubricantsused in rodent forging incustnpinclude, water, raineral al, Soap. sav dist graphite. molybdenum disulfide, and liquid glass FORGING DEFECTS nspectigh 373A important aspect of metal forging manufacture. All pafts should be checked for defécts afte the ‘manafaéturing process is complete, Defeets of metal forged product includeexterior cracking, interior cracking, laps, cold shuts, Waspitig of the past, auproperly formed sections and dead zones. Cracking both interior and exterior is caused by excessive stress. or improper stress distribution as the partis being formed. Cracking of a forging can be the sesult of poorly designed forging die or excess material in the svork piece. Cracks can also be caused by disproportionate temperature distnbutions during the manufacturing ‘operation. High thermal gradients can cause cracks in a forged part Laps ox folds in 2 metal for ig 272 eatsed by a bueing GFthe pail laps can Be a reba of fap bitte miglehal in the wok piece Cold shuts occur when metal 6S of different tempesanires meet they do not combine aivothly. a boundary laye (eold shat) forms at eit intersection. Cold shuts indicate that there is @ problem with metal flowin the ‘mould as the pat 1s being formed. Warping of a forged part can happea whe thinner sections tool faster than the rest of the forging. Improperiformed sectious and'dead zones can B3la result oftoo little metal iv the Wok, piece or flawed forging die design resulting in incomrect material distribution during the process. ‘However. the main principle 1s to enaet the right material distnibutions. and the right material flow to accomplish these distributions. Die cavity geometry and comer radius playa lage role in the action of the metal flow |A brief description of other defects and their remedial method is given below (a) Unfilled’Seetion: In this Somerseetion of the die cayitvare noFeompletely filed byjthe*flogrine metaleThe causes of these defects are improper desian ofthe forzing die or using forzing tecimiques, (b) Cold Shiats This appears as sinallcracks at the comers of the foraing. Thus 1s ¢aused mainly by the imyoper desiga of die. Where the comer and the fillet radii we sauall the metal does not flaw properly fato,the comer and the ends Wp 22 a.e0ld cit. (©) Seale Pits; This 3 seen a3 ategular depressions om the surface ofitise fofeme. This is primary caused ‘because of improper cleaning of the stock used for forging The oxide and scale gets'embedded into the finish forging surface When the forging is cleaned by pickling. chese are seen as depurations on the forging surfaceME 602 PRODUCTION ENGINEERING III ABPURI 14 (@ Die Shift: Ths is caused by the miss alignment of the die halve, making the two halve of the forging to be 2FORGEABILITY OF METALS ‘One popular test involves compressing a eylindtical work stock between to fat die, This is called ypserrng the ‘work, thus this testis called the upsetting test. In an upsetting test, the work stock is compressed by flat open die redacng the workin height enti cracks form. The amount of edutin cin be considered a measiremeat of However, frgablity tet em alo detentine other agave effet that amie may exhibit under ferent conditions of stress, strain rate, and temperature. #:DIE_ MANUFACTURING METHODS ‘+ Die quality and life are significant aspects ofthe total manufacturing operation and quality of the parts ele for surface finish and dimensional accuracy