My Forging

FORGING:Forging
is a process in which
material is shaped by the application of localized
compressive forces exerted manually or with power
hammers, presses or special forging machines. The
process may be carried out on materials in either hot
or cold state. When forging is done cold, processes
are given special names. Therefore, the term forging
usually implies hot forging carried out at
temperatures which are above the recrystallization
temperature
of
the
material.
Grain Structure:
# Parts have good strength
# High toughness
# Forgings require additional heat treating
Fig : A part made by three different procedures,

showing grain flow (a) casting (b) machining (c)
forging
Forging is an effective method of producing many

useful shapes. The process is generally used to
produce discrete parts. Typical forged parts include
rivets, bolts, crane hooks, connecting rods, gears,
turbine shafts, hand tools, railroads, and a
variety
of
structural
components
used
to
manufacture machinery. The forged parts have

good strength and toughness; they can be used
reliably for highly stressed and critical applications.
Common forging processes :

1.Open die hammer forging
2. Impression die drop forging
3. Press Forging
4. Upset Forging
5. Swaging
6. Roll forging
Open Die Hummer Forging: It is the simplest forging

process which is quite flexible but not suitable for large
scale production. It is a slow process. The resulting size
and shape of the forging are dependent on the skill of the
operator.
Open die forging does not confine the flow of

metal. The operator obtains the desired shape of
forging by manipulating the work material between
blows. Use may be made of some specially shaped
tools or a simple shaped die between the work piece
and the hammer or anvil to assist in shaping the
required sections (round, concave, or convex),
making holes, or performing cut off operations.
This process is most often used to make near
final shape of the part so that some further operation
done on the job produces the final shape.
Forging Force:
Inopendieforgingoperation,
theforgingforceF,tobeappliedonasolidcylindrical
component can be determined from the relation.
Where: s f is the flow stress of the material, is
the coefficient of friction, and d and h are the
diameter and height of the work piece.
Example: Using open-die forging operation, a solid

cylindrical piece of 304 (Type of Steel) stainless steel
having 100 mm dia. x 72 mm height is reduced in the
height to 60 mm at room temperature. Assuming the
coefficient of friction as 0.22 and the flow stress for this
material at the required true strain as 1000 MPa, calculate
the forging force at the end of stroke.
Solution . Initial diameter = 100 mm
Initial height = 72 mm
Final height = 60 mm
If final diameter is d, (100)2 x 72 = d2 x 60
i.e. d =110 mm
Impression Die Drop Forging (Closed

Die Forging): 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.
Impression-Die & Closed-Die Forging
Forging Force Requirement: The forging force, F,

required to forge material by impression die forging
operation can be determined by the relation
F = k. s f. A
where k is a constant (whose value can be taken from
Table. s f is the flow stress of material at the forging
temperature, and A is the projected area of the forging
including the flash.
In hot forging of most non ferrous metals and
alloys, the forging pressure is generally in the range of 500
MPa to 1000 MPa.
Table: Range of value of k
1. Simple shape of part, no flash produced = 3 to 5
2. Simple shape of part, flash produced = 5 to 6
3. Intricate shape of part, flash produced = 8 to 12
Press Forging: Press forging, which is mostly

used for forging of large sections of metal, uses
hydraulic press to obtain slow and squeezing action
instead of a series of blows as in drop forging. The
continuous action of the hydraulic press helps to
obtain uniform deformation throughout the entire
depth of the work piece. Therefore, the impressions
obtained in press forging are more clean. Hydraulic
presses are available in the capacity range of 5 MN
to 500 MN but 10 MN to 100MN capacity presses
are more common.
Hydraulic press
Upset Forging:
Upset forging involves

increasing the cross section of a material at the
expense of its corresponding length. Upset
forging was initially developed for making bolt
heads in a continuous manner, but presently it is the
most widely used of all forging processes. Parts can
be upset forged from bars or rods up to 200 mm
in diameter in both hot and cold condition.
Examples of upset forged parts are fasteners,
valves,
nails,
and
couplings.
SWAGING:
In this process, the diameter of a

rod or a tube is reduced by forcing it into a
confining die. A set of reciprocation dies provides
radial blows to cause the metal to flow inward and
acquire the form of the die cavity. The die
movements may be of in and out type or
rotary. The latter type is obtained with the help of a
set of rollers in a cage, in a similar action as in a
roller bearing. The work piece is held stationary
and the dies rotate, the dies strike the work piece at
a rate as high as 10 - 20 strokes per second.
Typical parts made by swaging
In tube swaging, the tube thickness and / or

internal diameter of tube can be controlled with the
useofinternalmandrels.Forsmalldiametertubing,a
thin rod can be used as a mandrel; even internally
shaped tubes can be swaged by using shaped
mandrels. Fig. on next slide shows the process.
(a) Swaging of tubes without a mandrel. Wall

thickness
is
more
in
the
die
gap.
(b) Swaging with a mandrel. The final wall
thickness of the tube depends on the mandrel
diameter.
(c) Examples of cross-sections of tubes produced
by
swaging
on
shaped
mandrels.
Roll Forging: This process is used to reduce the thickness

of round or flat bar with the corresponding increase in
length. Examples of products produced by this process
include
leaf
springs,
axles,
and
levers.
The process is carried out on a rolling mill that has
two semi cylindrical rolls that are slightly eccentric to
the axis of rotation. Each roll has a series of shaped grooves
on it. When the rolls are in open position, the heated bar
stock is placed between the rolls. With the rotation of rolls
through half a revolution, the bar is progressively squeezed
and shaped. The bar is then inserted between the next set of
smaller grooves and the process is repeated till the desired
shape and size are achieved.
Coining:
# Closed-die forging process

# Used mainly for minting coins & making of jewelry
# Lubricants are not employed in this process because they
can get entrapped in the die cavities

My Forging

Uploaded by

Copyright:

Available Formats

My Forging

Uploaded by

Document Information

Original Title

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

My Forging

Uploaded by

Copyright:

Available Formats

FORGING:Forging

Fig : A part made by three different procedures,

Forging is an effective method of producing many

manufacture machinery. The forged parts have

Common forging processes :

Open Die Hummer Forging: It is the simplest forging

Open die forging does not confine the flow of

Example: Using open-die forging operation, a solid

Impression Die Drop Forging (Closed

Impression-Die & Closed-Die Forging

Forging Force Requirement: The forging force, F,

Press Forging: Press forging, which is mostly

Upset forging involves

In this process, the diameter of a

Typical parts made by swaging

In tube swaging, the tube thickness and / or

(a) Swaging of tubes without a mandrel. Wall

Roll Forging: This process is used to reduce the thickness

# Closed-die forging process

You might also like