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GENERAL DESIGN

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.

Power hammers - 1. gravity type


2. power assisted type
Presses
- 1. crank press
2. screw press
3. hydraulic press

TYPES OF FORGING

1. Hand forging made by successive blows with

simple die cavities. Operator manipulates work


piece to form a fairly crude approx. of the
finished part.
2. Blocker forging work piece is formed between
two dies with shaped impressions in them. It
closely resembles the finished part and are more
refined
3. Conventional impression die forgings more
refined than blocker ones . It can be made from a
blocker forging or directly from a heated metal
billet.

4. Precision forgings they are further more refined. They


are produced by a succession of forgings in dies with
shaped impressions. Difficult to differentiate from
conventional ones.
5. Cored forging here additional die elements along with
two opposing impression dies or clamping dies apply the
metal forces. Rams or shaped dies act upon work piece
forming may be an extrusion or upsetting. Here tighter
design tolerances are possible.
6. Ring rolling similar to hot rolling of bar or rod except
that it progresses repetitively on the same piece of a metal
which assumes a ring shape. Rectangular or contoured
cross sections are produced.
7. Roll forging here a relatively long, thin work piece is fed into
power driven rolls which may be shaped to vary the section
along its length.

Characteristics of Forging

Controlled grain structure sets forging apart from other processes.


With proper design ,it is possible to align grain flow with
directions of the principle stresses that will occur when the part is
loaded in service.
GRAIN FLOW is the directional pattern that metals crystals
assume during plastic deformation.
Strength ,ductility and impact resistance along the grain are
significantly higher than they would be in randomly oriented
crystals of cast metal or weld metal.
Because hot working refines grain structure ,physical properties
are also improved across the grain.
Forging assures structural integrity from piece to piece. Internal
pockets ,voids ,inclusions ,laps and similar flaws are easier to
avoid by good 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.

Moving parts are forged to reduce inertial forces and


parts that must be supported by other structures are
forged to reduce overall weight and complexity.
Parts that people lift and handle are forged to reduce
weight.
Parts whose failure would cause injury and
expensive damage are forged for safety.
Decorative parts are produced from forgings to
reduce scrap losses and ensure a platable surface.

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.

No portion of the parting line should


incline more than 75 degree from the
parting plane and much shallower
angles are desirable
Select a parting line that will not entail
any undercuts in either die impressions
as the forging must come out of the die
after it is made
Because metal flow at the parting line is
outward into the flash gutter, grain flow
in the forging has a corresponding
pattern
Depending on the way in which the part
will be loaded, it may be desirable to

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.

Sometimes, a parting line location


presents tapered surfaces automatically
because of the a parts shape.
For example, a cylinder lying parallel to
the parting plane has such natural draft
except for small bands next to the
parting line
Low draft and no draft forgings can be
produce in some metals such as
aluminium and brass.

4) Ribs, Bosses, Webs and Recesses


Metal flow is relatively easy to manage
when ribs and bosses are not too high
and narrow
It is the easiest when the web is
relatively thick and uniform in thickness
Forging becomes more difficult when
large amounts of metal must be moved
out of a relatively thin web into deep
ribs and high bosses
It is helpful to taper such webs toward
the ribs and bosses
Deep recesses are easier to forge if they
have spherical bottoms

When successive forging operations are


required it is advantageous to design for
a fairly large punch out hole in the thin
web section
During finish forging, after the hole has
been punched, flash flows inward at its
edges and helps to relieve excessive die
forces
Surface texture, designs, and lettering
on forged surfaces are simply very small
ribs and recesses
These features are located on surfaces
that are nearly perpendicular to die
motion as possible and locate them

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

If metal flows past a sharp corner and


then doubles back, the forging may be
flawed with a lap or cold shut and the
die may not fill completely
This is more likely if the sharp die corner
or sharp fillet radius in the forging is
near the edge of the piece
While all the radii should be ample for
easy forging, they can be made smaller
in readily forgeable metals
The deeper the impression, the larger
the radius should be, both at the fillet
around which metal must flow and at the
corner which must fill with metal

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

7) Other Forging Processes


Several of the limitations of impression
forging made in two part dies can be
bypassed and eliminated by upset or
cored forging techniques
Shapes that constitute undercuts for the
two part dies can be forged easily
Sharp external corners are feasible
Draft can be reduced, and no draft at all
may be possible on some surfaces

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

SUITABLE MATERIALS FOR


FORGING

Most metals and alloys can be forged at


elevated temperatures.
However the ease with which they deform
plastically varies widely.
Some alloys remain strong even when
heated upto its melting point
Some have high co-efficient of friction at
forging temperature and it is difficult to
slide them along die surfaces
Materials may be susceptible to
metallurgical degradation or to the
formation of mechanical flaws in course of
hot working

Alloys of aluminium, magnesium, copper and


mild steel are readily forgeable.
There are differences among them, but some
of these tend to balance out.
For example, aluminium can be forged at
lower temperatures than steel, but it flows
less readily and requires higher pressures
Stainless steel is resistant to plastic flow but
they are produced by conventional forging
Super alloy forgings are used to produce only
simpler shapes
If any part requires elaborate contours or
drastic section changes, then these features
must be provided in subsequent operations.

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

2) Die Wear Tolerance


These tolerances aply only to dimensions
generally parallel to the parting plane and
perpendicular to the die motion
The corresponding variations parallel to die
motion are included in the die closure
tolerances
Die wear tolerances are plus variations of
external dimensions and minus variations of
internal dimensions
They allow for erosion of die metal and
corresponding enlargement of forged parts
Multiply each horizontal dimension by the
appropriate factor, and round off the
tolerance to the next higher mm.

3) Die Closure Tolerances


Dimensions parallel to die motion
between opposite sides of a forging are
affected by failure of the two die halves
to close precisely
There is no minus tolerance in this
category
Effects of die wear on these vertical
dimensions are included in the die
closure tolerances
An added tolerance of 0.3% applies to
any projection that extends more than
150mm from the parting plane.

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

6) Flash Extension Tolerances


The most common flash removal method is
by a punching operation in contoured dies
This may produce clean trimmed edges, but
a small bead of flash allowed.
They are specified in terms of forging weight
and alloy type.

7) Draft Angle Tolerances


Common tolerance on draft angles are
+2 degree to -1 degree.

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

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