Manufacturing Technology

MEC205
Forging
FUNDAMENTALS OF METAL FORMING
Forging
• Is a metal deformation process in which
metal is transformed into useful shape by
hammering or pressing.
• It is a oldest metal working art( e.g
Blacksmithy)
• Forging machines are now capable of
making parts ranging in size of a bolt to a
turbine rotor.
• Most forging operations are carried out hot,
although certain metals may be cold-forged
FUNDAMENTALS OF METAL FORMING
Forging
• Forging is basically involves plastic
deformation of material between two dies
to achieve desired configuration.
• Depending upon complexity of the part
forging is carried out as open die forging
closed die forging, and flashless forging.
FUNDAMENTALS OF METAL FORMING
Forging
1. Open die forging
• It is hot mechanical forming in which workpart is deformed
between flat or shaped dies in which the metal flow is not
completely restricted
• Deformation operation reduces height and increases diameter of
work

Fig (1) start of process, (2) partial deformation, and (3) final shape
FUNDAMENTALS OF METAL FORMING
Forging
1. Open die forging
• Common names include upsetting or upset forging
• Friction between work and die surfaces constrains lateral flow of
work, resulting in barreling effect

Fig (1) start of process, (2) partial deformation, and (3) final shape
FUNDAMENTALS OF METAL FORMING
Forging
2. Closed die forging/impression forging
• Compression of workpart by dies with inverse of desired part
shape
• Flash is formed by metal that flows beyond die cavity into small
gap between die plates

Fig : (1) just prior to initial contact with raw workpiece, (2) partial compression, and (3) final
die closure, causing flash to form in gap between die plates
FUNDAMENTALS OF METAL FORMING
Forging
2. Closed die forging/impression forging
• Flash must be later trimmed, but it serves an important function
during compression
• As flash forms, friction resists continued metal flow into gap,
constraining material to fill die cavity

Fig : (1) just prior to initial contact with raw workpiece, (2) partial compression, and (3) final
die closure, causing flash to form in gap between die plates
FUNDAMENTALS OF METAL FORMING
Forging
2. Closed die forging/impression forging

Advantages: Limitations:
• Higher production rates • Not capable of close
• Less waste of metal tolerances
• Greater strength • Machining often required

• Favorable grain orientation in the to achieve accuracies and

metal features needed

Q. Which of the following processes is not the type of bulk forming
process in the metal forming?
a) Bending
b) Rolling
c) Forging
d) Extrusion

Q. Which of the following manufacturing processes is mainly considered

for producing the components of very high strength?
a) Casting
b) Forging
c) Extrusion
d) Rolling
FUNDAMENTALS OF METAL FORMING
Forging
3. Flashless forging
• Compression of work in punch and die tooling whose cavity does
not allow for flash
• Starting workpart volume must equal die cavity volume within
very close tolerance

Fig: (1) just before initial contact with workpiece, (2)

partial compression, and (3) final punch and die closure.
FUNDAMENTALS OF METAL FORMING
Forging
3. Flashless forging
• Best suited to part geometries that are simple and symmetrical
• Often classified as a precision forging process

Fig: (1) just before initial contact with workpiece, (2)

partial compression, and (3) final punch and die closure.
FUNDAMENTALS OF METAL FORMING
Forging Hammers(Drop Hammers)
Apply impact load against workpart
Two types:
1. Gravity drop hammers - impact energy from falling weight of a
heavy ram
2. Power drop hammers - accelerate the ram by pressurized air or
steam
Disadvantage: impact energy transmitted through anvil into floor of
building
• Commonly used for impression-die forging
FUNDAMENTALS OF METAL FORMING
Forging Hammers(Drop Hammers)

Fig Drop forging hammer, fed by conveyor and heating units at the right of
the scene (photo courtesy of Chambersburg Engineering Company).
FUNDAMENTALS OF METAL FORMING
Forging Presses
Apply gradual pressure to accomplish compression operation
Types:
1. Mechanical press - converts rotation of drive motor into linear
motion of ram
2. Hydraulic press - hydraulic piston actuates ram
3. Screw press - screw mechanism drives ram
FUNDAMENTALS OF METAL FORMING
Upsetting and Heading
Forging process used to form heads on nails, bolts, and similar
hardware products

The cycle consists of: (1) wire stock is fed to the stop, (2) gripping dies close on the stock
and the stop is retracted, (3) punch moves forward, (4) bottoms to form the head
FUNDAMENTALS OF METAL FORMING
Heading

Examples of heading (upset forging) operations: (a) heading a nail

using open dies, (b) round head formed by punch, (c) and (d) two
common head styles for screws formed by die, (e) carriage bolt head
formed by punch and die
FUNDAMENTALS OF METAL FORMING
Forging Defects
1) Incomplete forging penetration:
Cause-Use of light rapid hammer blows
Remedy-Touse forging press for full penetration.
2) Surface cracking:
Cause-Excessive working on the surface and too low
temperature.
Remedy-To increase the work temperature
FUNDAMENTALS OF METAL FORMING
Forging Defects
3) Cracking at the flash:
This crack penetrates into the interior after flash is trimmed off.
Cause-Very thin flash
Remedy-Increasing flash thickness
4) Cold shut (Fold):
Two surfaces of metal fold against each other without welding
completely.
Cause-Sharp corner (less fillet), excessive chilling, high friction
Remedy-Increase fillet radius on the die
FUNDAMENTALS OF METAL FORMING
Forging Defects
5. Die shift (Mismatch): Misalignment of forging at flash line.
Cause-Misalignment of the die halves.
Remedy-Proper alignment of die halves
6. Scale Pits (Pit marks):Irregular depurations(removal of
impurities) on the surface of forging.
Cause-Improper cleaning of the stock used for forging. The oxide
and scale gets embedded into the finish forging surface.
Remedy-Proper cleaning of the stock prior to forging.