MGM’s POLYTECHNIC

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SUBJECT : Manufacturing processes

SUBJECT
CODE : 17402
 Chapter 1
Forming processes
Instructional Objectives
Drop forging: Upset forging , press forging ( Die forging ) , Open die and close die forging , Forging operation .

Rolling : Principal of rolling , Hot and cold rolling , Types of rolling mill , Applications of rolling .

Extrusion : Direct and indirect extrusion , Advantages , Disadvantages and applications .

Define forging: Forging is defined as the process of plastically deforming metals to a specific shape by a
compressive force exerted by some external agency like hammer, press, rolls or by an upsetting machine of some
kind. The portion of the work in which forging is done is termed the forge and the work is mainly performed by
means of heavy hammers, forging machines, and presses

Types of forging :
1) Smith die forging a) Hand forging b) Power forging i) Hammer forging ii) Press forging .
2) Impression die forging a) Drop forging b) press forging c) machine forging .

Explain drop forging with neat sketch .

In this process a specified weight hammer is raised to definite height and is allowed to fall freely under it own
weight as shown in figure . The upper half of a die is mounted on the raised hammer and metal is placed over
the lower half of the die . In drop forging process , impression dies are used to control the shape and size . The
hammers used may be of gravity type or hydraulic type .
Explain upset forging ( Horizontal forging ) with neat sketch.
This is essential a cold forging process . it is based on upsetting cylinder bar in horizontal dies . Up setting
increases the diameter and reduces length .The die used are split construction the bar to be forged is introduced
in the die . Its length is controlled by a mechanical stop . On closing the dies grip bar firmly .A punch or
upsetting tool is mounted on the machine ram . On pressing the die the punch moves and upset the bar to the
shape of the die .

Explain press ( Die ) forging with neat sketch:

Forging of parts by press , involves slow squeezing of plastic metal . Hydraulic or mechanical presses are used
to carry out the operation . The operation is faster , The whole operation is carried out in a single squeezing
operation . Deep penetration is obtained because enough time is allowed to the metal to flow . More
complicated shapes with better dimentional accuracy can be forged .
Compere Press and Drop forging .
Sr Press forging Drop forging
,n
o
1 Slow squeezing action is produced by using a Rapid blow is produced by using mechanical hammer
press.

2 Less vibration & shocks on the structure, More vibration & shocks on the structure, foundation
foundation and nearby equipment’s due to and nearby equipment’s due to sudden impactive action.
squeezing operation.

3 Work need not be altered quickly as the Work should be altered quickly as the operation is of
operation is slow ( squeezing) rapid blows(hammering)

5 Press forging allows time to get forging effect Drop forging does not allow time to get forging effect
with uniform structure throughout which with uniform structure throughout, which will not
produces more dense structure. produce more dense structure ( Excess deformation to
out side with less than inner structure )

4 Press forging produces forging effect (change Drop forging operation may not produce forging effect
of shape) to deep portion as it is slow pressing to more deep ,especially for heavy jobs.
operation.

5 Highly skilled operator are not required . Skilled operator are required .
6 The life of die and press is more as compared The life of die and press is less as compared to press
to drop forging forging .
Explain open die forging with neat sketch.

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

Explain close die forging with neat sketch.

Impression die forging is also called as close die forging. Impression die s generally contains preliminary
shaping steps to permit the change from the original forging stock to the finished forging without mechanical
defects. Simple symmetrical parts may be forged directly in the finished impression (finishing die cavity)
without preliminary shaping.
 The process uses shaped dies to control the flow of metal. The heated metal is positioned in the lower cavity
and on it one or more blows are struck by the upper die. This hammering makes the metal to flow and fill the
die cavity completely. Excess metal is squeezed out around the periphery of the cavity to form flash. On
completion of forging, the flash is trimmed off with the help of a trimming die.

Most impression – die sets contain several cavities. The work material is given final desired shape in stages
as it is deformed in successive cavities in the die set. The shape of the cavities cause the metal to flow in desired
direction, thereby imparting desired fibre structure to the component.

Difference between open die and close die forging .

Sr.no Open die forging Close die forging
1 Open die forging is the process of deforming a Closed die forging (also referred to as impression die
piece of metal between multiple dies that do not forging) is a metal deformation process that uses
completely enclose the material. 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 tolerances and
need secondary machining and refining to need for heat treatment can determine the number of
achieve the tolerances required for the finished passes the product requires through the dies.
specifications.
3 Continuous compressive force required to stop One time compressive force required to shape the
the products. products.
4 Open dies are not too much expensive Closed dies are expensive
5 Open die forging technique is more suitable for Closed die forging technique is more suitable for
large parts in a number of tons small parts

What are different forging operation .

Irrespective of the forging method employed there are certain basic operations which can be identified in all
forgings . These operation are as shown in

1) Upsetting involves increasing the cross section and decreasing height .

2) Horizontal upsetting is done in a horizontal close die .
3) Heading consist of partial or end upsetting .
4) Drawing out consist of reducing the section and increasing length .
5) Fullering consist of reducing thickness and spreading the material obtained larger section .
6) Bending straight bar is bend at desired angle .
7) Piercing creates a hole by using a piercing tool or punch .
8) Shearing The bar is sheared or offset .
9) Ring forging creates a ring from a bar . The end are forge welded .

Fullering:
Fullering is used to reduce the cross-sectional area of a portion of the stock. The metal flow is outward and
away from the centre of the fuller. i.e., forging of connecting rod for an internal combustion engine.
 Rolling

Define rolling:
Rolling is the process in which metal and alloys are plastically deformed into semi-finished or finished
condition by passing them between circular or contoured cylinders. The deforming metal is subjected to high
compressive force from squeezing action of the rolls.

Explain rolling with neat sketch.

Rolling is a process where metal is compressed between two rotating rolls for reducing its cross section
area. The metal is taken into rolls by a friction and subsequently compressed to obtain the final shape
.The thickness of the metal that can be drawn depends on the roughness of the roll surface. The
reduction that could achieve with the set of rolls is designated as the angle of bite is shown in figure.
This depends on the type of rolling and the condition of the roll. The volume of the metal that enters
the rolling stand should be same as that leaving it except in initial passes when there might be some
loss due to filling of voids and cavities in the ingots. Since the area of the cross section gets decreased
the metal leaving the rolls would be at the higher velocity than when it entered. The pressure on the
rolls gradually builds up from entry to the neutral point where it is the highest and then decreases till it
reaches the exit.

Compare hot rolling and cold rolling.

Sr ,no Hot rolling Cold rolling
1 It is carried out above the recrystalization It is carried out below the recrystalization temperature
temperature
2 No internal or residual stresses are set up Residual or internal stresses are setup in the metal
3 No cracks and blow holes are develops in Existing cracks propagates and new
the workpiece.
4 Dimensional accuracy is less Dimensional accuracy is more
5 It requires less power/force. It requires more power/force.
6 It is used for structural, sections, channels It is used for rods, sheets, plates, bars etc.
production etc

Tow high roll mill:

The simplest type is a two high mill having two rolls . Generally both rolls are driven . Unless they are
reversing type , the rolling can be done only one direction . These mills are used for heavy reduction .
Three high roll mill:-
The three high rolling stand arrangement is shown in fig. it consists of three horizontal rolls,
positioned directly one over the other. The direction of rotation of the upper and lower rolls are the
opposite, but the intermediate roll rotates in a direction same to both of these. All the three rolls
continuously revolve in the same fixed directions and never reversed. The work piece is fed in one

Four High Rolling Mill:-

it consists of four horizontal rolls, two of similar diameters and two of larger diameter, arranged directly one
over the other as shown in fig. the larger diameter rolls are called back up rolls and their main function is to
prevent the deflection of the smaller rolls, which otherwise would result in thickening of rolled plates or sheets
at the centre. The smaller rolls are known as working rolls and they are the rolls which concentrate the total
rolling pressure over the metal. These mills are generally used for subsequent rolling of slabs
Cluster mill :
Uses a large number of supporting rolls to further minimize the roll distortion . These mills are used for the
production of very thin sheets and foils .

Application of rolling:
 Extrusion

Define extrusion. State its type.

Extrusion is a process in which a heated billet of metal is forced by high pressure through an orifice that is
shaped to provide the desired form to the finished part.
Types of extrusion:
1. Direct or forward extrusion
2. Indirect or backward extrusion
3. Tube extrusion
4. Impact extrusion

Explain forward extrusion with neat sketch .

The equipment consists of a cylinder or container into which the heated metal billet is loaded. One end of the
container, the die plate with necessary opening is fixed. From the other end plunger or ram compresses the
metal billet against the container walls and die plate, thus the forcing it to flow of metal in the forward direction
through the die opening. Acquiring the shape of the opening the extruded metal is then carried by the
metal is then carried by the metal handling system as it comes out of the die. A dummy block which is a steel
disc of about 40mm thick with a diameter slightly less than container is kept between the hot billet and the ram
to protect it form heat and pressure. In direct extrusion, the problem of friction prevalent because of the relative
motion between heated metal billet and cylinder walls. To reduce this friction lubricants are to be used. To
reduce the damage to equipment, extrusion is finished quickly and the cylinder is cooled before further
extrusion.

Explain backward extrusion with neat sketgh .

In this process, the metal flows in the opposite direction of the ram. The ram in this process is hollow one. Die
is mounted over hollow ram which is referred as punch. The die is attached to the ram and pushed into the
billet which is stationary inside the container. During process there is no friction between the metal billet and
cylinder walls. Extrusion force required less as compared to direct extrusion but the press machine is
complicated as compared to direct extrusion. As compared to direct extrusion, this method finds limited
application .

Application of Extrusion:

A wire in circular section with small required diameter are prepared using rods of bigger diameter .It is allowed
to pass through the die on application of tension to the wire This process is always cold working process .The
end of the rod is reduced and made a point shape and inserted through the die opening . This end is then
gripped on the outer side with gripper which than pull the wire through the die .

Advantages of Extrusion:
1) It is fast process .
2) Can produced parts in large quantity .
3) With low cost .
 4) Little waste of metal .

Disadvantages of Extrusion :
1) Lubrication of parts necessary .
2) In hot extrusion temperature of raw material is to be maintained .
3)