Deformation Processes

Forging
 Deformation Processes
 Deformation processes in manufacturing are operations that induces
shape changes on the work piece by plastic deformation under
forces applied by various tools and dies
Classification according to size and shape of specimen
 Surface Area to volume OR Surface Area to thickness Ratio
Bulk Deformation
 Surface Area to thickness ratio is small, cross-section of the work
piece changes
Sheet Forming
 Surface Area to thickness ratio is high, thickness changes are
undesirable
 Examples

 Extrusion
 Drawing
 Rolling
 Forging
 Extrusion

 A round billet is placed in a chamber and

forced through a die opening by ram. The
die may be round or of various shapes
Extrusion Dies
 Examples

Extrusion and examples of products made by sectioning off extrusions

Drawing
Rolling
 Forging

A family of processes by which plastic deformation is

carried by compressive forces

Open-die Forging (Upsetting)

Placing a solid cylindrical work piece between two flat
dies and reducing its height by compressing it

Impression die forging

The work piece acquires the shape of die cavities
(impressions)
Open-die Forging (Upsetting)
Impression-Die Forging
Forging A Connecting Rod
 Closed die forging
In closed-die-forging, no flash is formed and the
workpiece is completely surrounded by the dies.

 Therefore, proper control of the volume of

material is essential to obtain a forging of desired
dimensions. Undersized blanks in closd-die

 forging prevent the complete filling of the die,

while oversized blanks may cause premature die
failure or jamming of the dies.
 Advantages of Forging
 Impact Strength: Through proper grain flow orientation, the forging
process can develop the maximum impact strength and fatigue resistance
possible in a metal.

 Structural Integrity:. There are no internal gas pockets or voids

that may cause unexpected failure under conditions of high stress or impact.
It is well known a forging's structural reliability is excelled by no other
metalworking process

 Size Range: Forged parts are economically produced in a broad range

of sizes and shapes.

 Uniformity: The consistency of material and dimensions from one

forged part to the next, and from separate production lots of forgings
produced months or years apart, is extremely high. Forgings are made
through a carefully controlled sequence of production steps, in contrast to a
random flow of material into the desired shapes. Uniformity in composition
and structure, piece to piece, insures reproducible response to heat
treatment, minimum variation in machinability, and consistent property
levels of finished parts.
 Strength-To-Weight Ratio:
The higher strength-to-weight ratio can be used
to reduce section thickness in part design.

 Economic Advantages:
Forging's superior functional advantages of
strength, fatigue resistance, reliability, and high
quality combine into economic benefits. Uniform
dimensional relationships result in consistent
machinability and predictable response to heat
treatment. This, combined with obvious
strength-to-weight ratios, make forgings a top
priority of the cost-conscious user.

 Good surface finish.

 Applications of Forging

 Automotive & Truck

 Agricultural Machinery & Equipment
 Valves, Fittings, Oil Field Applications
 Hand Tools & Hardware
 Off-Highway Equipment/Railroad
 Ordnance/Shipbuilding
 Aerospace
 Forgeability

 The forgeability of a metal can be defined

as its capability to undergo deformation by
forging without cracking
 Metal which can be formed easily without
cracking, with low force has good
forgeability.
 Tests to determine forgeability
 Upsetting test OR Compression Test :
cracks while upsetting cylindrical specimen
 Various temperatures and strain rates
 Just provides guidelines
 Hot-twist test
 Metal rod is twisted at various temperatures.
 Forgeability can be determined for different materials
using this method.
 Used for steel.
 Lubrication during forging
1- Reduces die wear
2- Affects the flow in the die cavity
3- Serves as a parting agent and prevents sticking
4- Reduces friction and as a result saving energy

Examples of hot forging lubricants: Graphite, Molybdenum, Glass

Examples of cold forging lubricants: Mineral oil, water, soap