Forming Processes

FORMING PROCESSES
Define forging operation. Classify it.
Forging is defined as controlled plastic deformation of metals at elevated temperatures

into a pre-determined size or shape using compressive forces exerted through some type of die
by a hammer or press.
Classification according to forging method
1. Drop forging
2. Press forging
3. Hot bar forging
4. Upset forging
5. Swing forging
6. Cored forging
7. Rotary forging.
What is Upset Forging?
It is the operation of increasing thickness of bar by corresponding reduction in its length.

The bar is heated held on anvil, swage block or vice and end pressure is applied by hitting with a
hammer.
The effects produced are shown in fig. a) by heavy hammering, (b) by light hammering,
(c) & (d) by local heating and hammering.
Write applications of forging operation.
1. Forge is used in mechanism and machines wherever a component require high strength.
2. Various automotive application including crankshaft, connecting rod, piston etc.
3. Used in mining, agricultural equipment as well as in aircraft.
4. Used in steam turbine, food processing etc.
Explain is Open Die Forging?
Open die forging is the process of deforming a piece of metal between multiple dies that do not
completely enclose material. The metal is altered as the dies hammer the material through a series of
movements. Until desired shape is achieved Products formed through open die forging needs secondary
machining. Open die forging used for short run forgings of parts that are simple. The repeated working
of the material through this process increases strength of grain structure It reduces voids. The
operations in open die forging are up setting, drawing out, bending, piercing, spreading etc. If the open
die is used in smith forging, by hand on anvil, then process is called as Hand forging. And when open die
is used in press then it is called press forging. The main advantage of open die is its very low cost
Compare Press forging & Drop forging.
Sr. Press forging Drop forging

No
1 In this process steady pressure is applied In this process metal fills in the cavity of die
slowly over the metal so that metal is slowly completely and it takes the final shape
and gradually take final shape. It is also after giving the impact.
called as die forging.
2 More complicated shapes can be forged. It is used for simple shape produce.
3 The life of dies and press is more as The life of dies and press is less as compare
compare to drop Forging. to press forging due to repeated
blows/impacts
4 The press forging is faster than drop forging The drop forging is slower than press
and cost of operation also lower. forging, as total change is not achieved in
one blow. Hence cost of operation is more.
5 Highly skilled operator not required. Required skilled operator
6 Less vibrations are observed More vibrations are observed
Differentiate between open die and closed die forging.
Sr. Open Die Forging Closed Die Forging

No
1 Open die forging is the process of deforming Closed die forging (also referred to as
a piece of metal between multiple dies that impression die forging) is a metal
do not completely enclose the material. deformation process that uses pressure to
compress a piece of metal to fill an
enclosed die impression.
2 Products formed through open forging often The type of material, tightness of
need secondary machining and refining to tolerances and need for heat treatment can
achieve the tolerances required for the determine the number of passes the
finished specifications. product requires through the dies.
3 Continuous compressive force required to One time compressive force required to
shape the products shape the products
4 Open die forging technique is more suitable Closed die forging technique is more
for large parts in a number of tons suitable for small parts
5 Open dies are not too much expensive Closed dies are expensive
List various forging operations.
1. Upsetting 2. Heading 3. Bending
4. Fullering 5. Drawing Down 6. Punching
Upsetting:
It is a forging operation where metal piece thickness or diameter increases & length of
bar or piece reduces.
Bending:
It is one of the important operation in forging & is very frequently used. Sharp corner
bends or curve can be formed. It is performed by hammering the metal over the edge of
anvil or vice using metal blocks. Metal may be bent into various shapes without damage to
the structure.
Fullering:
Fullering is primary forging operation where bar is elongated between two fullers along
its length. It reduces the cross section of the bar and lengthen the portion of stock.
Punching:
Punching is a forging operation of making square or cylindrical holes by using hot punch.
It can be carried out over pitched hole of anvil or cylindrical die or over swage block.
State the rolling principle with neat sketch.
Rolling is the process in which the metals and alloys are plastically deformed into semi-
finished or finished condition by passing them between circular or contoured rotating cylinders.
The deforming metal is subjected to high compressive force from squeezing action of the rolls.
Draw neat sketch of two high rolling mill.
Draw neat sketch & explain four high rolling mill.
This type of machine consists of four rolls, two smaller in size and other two bigger in size. The
actual rolling is done by small size wheels and other two bigger wheels provide backup and
necessary rigidity to the smaller rolls. This mill is commonly used for hot as well as cold rolling of
plates and sheets. By this rolling process different types of shapes are formed. Those are I-section,
T-section, etc.
Write applications of rolling.
1. Different types of shapes are formed such as I-section, T-section, L-section, Channel section etc.
2. Special section such as railway wagon wheels is produced by rolling.
3. Bars of all shapes, rods, sheets etc.
Draw neat sketch & explain thee high rolling mill.
It consist of three horizontal rolls, positioned directly one over the other. The direction
of rotation of the upper and lower rolls are the same , but the intermediate roll rotates in a
direction apposite to both of these all the three rolls continuously revolve in the same fixed
directions and are never reversed. The work piece is fed in one direction between the upper
and middle rolls and in the reverse direction between the middle and lower rolls. Many pieces
may be passed through the rolls simultaneously. This results in a higher rate of production than
the Two High Mill. This mill may be used for blooming, billet rolling or finished rolling.
Compare Hot Rolling & Cold Rolling.
Sr. Hot Rolling Cold Rolling

No
1 It is carried out above the recrystallization It is carried out below the recrystallization
temperature temperature
2 No internal or residual stresses are set up Residual or internal stresses are setup in
the metal
3 Improved Mechanical properties Process leads in to distortion of grains
4 No cracks and blow holes are present in the Existing cracks propagates and new cracks
metal may developed
5 Close dimensions can’t be maintained Superior dimensional accuracy can be
obtained
6 It requires less power for rolling It requires more power for rolling
7 It is used for plates, bars, structural sections, It is used for rods, sheets, plates bar etc.
channels production.
Explain with neat sketch Forward or Direct Extrusion Process.
It is the most widely used method and the maximum numbers of extrusion parts are
produced by this method. The row material used is a billet. It is heated to its forging
temperature and fed in to the machine chamber; pressure is applied to the billet, forcing the
material in to Die. The length of extrusion part will depend on the size of the billet and cross
section of the die. The extrusion part is then cut to the required length.
Explain with neat sketch Backward Extrusion Process.
For this type of extrusion the ram or plunger used is hollow, and as it presses the billet
against the back wall of the closed chamber the metal is extruded back into the plunger. As the
billet does not move inside the chamber, there is no friction between them.
Compare Direct & Indirect Extrusion.
Sr. Direct Extrusion Indirect Extrusion

No
1 Flow of metal through die & ram movement Flow of metal is in the direction opposite to
are in same direction. ram movement.
2 It requires more force. It requires less force.
3 A large amount of friction exists between There is no friction between & cylinder
billet & cylinder walls. walls.
4 It is simple in design & construction It is complicated in design & construction.
5 The process finds wide applications. It has limited applications.
State the applications of Extrusion Process.
1. It is mostly employed on non-ferrous metals like aluminum, copper & magnesium.

2. Production of seamless tubes
3. Variety of cross-sectional shapes such as circular, square, rectangular etc. can be
produced.
4. Channel sections, I Sections, Z- Sections, T- Sections can be produced.
5. Tubes & Pipes of complex Configuration.

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FORMING PROCESSES

Define forging operation. Classify it.

Forging is defined as controlled plastic deformation of metals at elevated temperatures

What is Upset Forging?

It is the operation of increasing thickness of bar by corresponding reduction in its length.

Write applications of forging operation.

Compare Press forging & Drop forging.

Sr. Press forging Drop forging

Sr. Open Die Forging Closed Die Forging

List various forging operations.

1. Upsetting 2. Heading 3. Bending

4. Fullering 5. Drawing Down 6. Punching

Draw neat sketch of two high rolling mill.

Draw neat sketch & explain four high rolling mill.

Draw neat sketch & explain thee high rolling mill.

Sr. Hot Rolling Cold Rolling

Explain with neat sketch Forward or Direct Extrusion Process.

Compare Direct & Indirect Extrusion.

Sr. Direct Extrusion Indirect Extrusion

State the applications of Extrusion Process.

1. It is mostly employed on non-ferrous metals like aluminum, copper & magnesium.

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