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RECOMMENDATIONS FOR
FORGING
Seminar By:
1.Arun A
2.Arun Das C
3.Jeson M F
4.Kiran V
5.Laluprasad E
6.Lin John
7.Mahesh M
8.Raja Ram P K
9.Sivaprasad S
10.
Sreejith S
11.
Varun A
FORGING
Shaping of heated metal parts by plastic
deformation, usually with one or more strokes of
a power hammer or press.
TYPES OF FORGING
Characteristics of Forging
Applications of Forging
There are two classes of application of forging:
High strength to weight characteristics or high
strength needed in a part.
An economical means of producing the part
configuraion required.
Often these two classes overlap.
Main applications:
Used in aircrafts : Because of high strength and light
weight requirements ,makers of aircraft engines and
structures ,along with other aerospace manufacturers are
the most significant users of forging on a value basis.
FORGING NOMENCLATURE
Shapes on a forging are named for the direction
in which metal must flow to fill the die
impressions
Walls filled by flow parallel to the die motion is a
rib
A projection is called a boss when it is filled
parallel to die motion
Wall filled by horizontal flow, perpendicular to die
motion and parallel to the parting line is a web
A recess is a small web area surrounded by the
thicker metal
When die halves come together, the excess
metal is extruded into gutter at the parting line,
producing a fringe of flash metal around it
DESIGN
RECOMMENDATIONS
1) Forging Drawings
Most forgings are produced in two part
impression dies. The design of such forgings is
discussed.
Shapes and dimensions of part to be forged
before any machining is done are shown in this
drawing.
Die design and processing requirements are
expressed by the way in which the part is drawn
Flash is not indicated in the drawing
Alinging grain flow with principal load stresses
should be kept in mind
An experienced designer can visualise metal
flow and the resulting grain flow pattern
2) Parting Line
As the die halves come together and confine
metal in their cavities, their mating surfaces
define a parting line around the edges of the
forging
Parting line is indicated on the drawing and
determining its location is a critical step in
forging design.
Ideally parting line will lie in one plane
perpendicular to the axis of die motion
Sometimes it can be located so that one die half
will be completely flat and it will surround the
largest projected area of the piece
If the parting line cannot lie in one plane, it is
desirable to preserve symmetry so as to prevent
high thrust forces on the dies and the press.
3) Draft
Die impressions are tapered so that
forgings can be removed from their dies
So the forged surfaces that that lie
parallel to die motion are tapered
This taper is called draft
This draft also promotes flow into
relatively deep die cavities
Standard draft angle will be specified on
for all affected surfaces on a forging,
which simplifies tooling for die sinking
It is also conventional to call for matching
draft on both die halves to make surfaces
of unequal depth meet at the parting line.
5) Radii
Forgings are designed with radii on all
their external corners except at the
parting line
It would require a sharp internal angle in
the die to form a sharp corner on the
forging
This is a stress raiser and excessive
pressure is required to fill sharp corners
Common practice is to provide full radii
at the edges of all ribs and the same
radius on each corner of a boss, web or
other shape
Fillet radii on a forging correspond to
6) Machining Allowance
Design features that promote easy
forging add to the metal that must be
machined away
The machining allowance should allow
for the worst case buildup of draft, radii
and all tolerances
Extra metal is provided to keep critical
machined surfaces away from the grain
flow pattern that occurs in the flash
region near the parting line
Machining or finishing allowances are
added to external dimensions and
subtracted from internal dimensions
POINTS TO NOTED
It not practical to forge a through hole in a
web
When a hole through a web or a boss will be
needed, a recess may be forged in one or
both sides
The thin web remaining is punched out later
and the hole may be subsequently cleaned
up by machining
A forging should be dimensioned so that
enough metal will be available on every
surface to satisfy all the functional
requirements of the finished part
TOLERANCES
1) Length and Width Tolerance
Dimensions generally parallel to the
parting plane and perpendicular to die
motion are subject to length and width
tolerances
When a forged part extends more than
150mm from the parting plane,
dimensions to its extremities,
measured parallel to die motion are
also subject to these tolerances
Length and width tolerances are
commonly specified at +0.3% of each
dimension, rounded of to the next
4) Match Tolerances
A lateral shift of one die half with respect to
the other moves all the features on the
opposite sides of the forging correspondingly.
Tolerances are given in terms of piece weight
and material
5) Straightness Tolerances
For relatively long, thin parts, a straightness
tolerance of 0.3% of length is given
When this aspect of forging accuracy is
critical, forged parts are often straightened
out in secondary cold operations
8) Radii Tolerances
Normally the tolerance on all corner and fillet radii
is plus or minus one half of the radius
On any corner where metal will be removed later,
the plus radius governs how much metal will be left
for producing a sharp corner in final product
Minus tolerance limit sharpness of the forged
corner and is not enforced
9) Total Tolerances
The tolerances for each dimension are
arithmetic sum of all individual tolerances
that apply to surfaces involved
Other tolerances like draft, angle, radii,
mismatch are also additive as they affect
those surfaces