Cutting action in Press tools

The cutting of sheet metal in the press

work is a shearing process.
The punch is same shape as the die
opening except that it is smaller on each
side by an amount known as clearance.
 Die and Punch
A typical die and punch set is shown in Fig.

The sheet metal used is called strip or stock. The punch which is held in the
punch holder is bolted to the press ram while die is bolted on the press table.
During the working stroke, the punch penetrates the strip, and on the return
stroke of the press ram the strip is lifted with the punch, but it is removed from
the punch by the stripper plate.
The stop pin is a gage and it sets the advance of the strip stock within the punch
and die. The strip stock is butted against the back stop acting as a datum
location for the centre of the blank.
 Shearing is the process of cutting off of sheets using a die and
punch, applying shear stress along the thickness of the sheet. A die
and punch or a pair of blades are used in shearing.
Shearing happens by severe plastic deformation locally followed by
fracture which propagates deeper into the thickness of the blank.
The clearance between the die and punch is an important
parameter which decides the shape of the sheared edge.
Large clearance leads to rounded edge.
The shearing load is also higher for larger clearance.
For harder materials and larger sheet thickness, larger clearances
are required.
 Generally, clearance can vary between 2% and 8% of the sheet
thickness.
The clearance angle provided on the die depends on the material of
stock, as well as its thickness.
For thicker materials generally higher angular clearance is given. In
most cases, 2 degree of angular clearance is sufficient.
 Die clearance
The die opening must be sufficiently larger than punch to permit a clean fracture
of the metal.
The difference in dimensions between the mating members of the die set is called
clearance.
The clearance is applied in the following manner:
When the hole has to be held in size i.e., the hole in the sheet metal is to be
accurate and slug is to be discarded, the punch is made to the size of the hole
and the die opening size is obtained by adding clearance to the punch size.
The clearance is the function of the kind, thickness and temper of the work
material, harder materials requiring larger clearance than soft materials, the
exception being aluminum.
The clearance may be determined by
c = 0.0032 t. (Ts)1/2
where Ts is the shear strength of the material in N/mm 2
 Clearance in blanking

Constant , which is equal to 0.0032

Clearance in Piercing
 Types of dies
Dies are classified according to the type of press operation and
according to the method of operation.
According to the type of the press operation, dies are classified as cutting
dies and forming dies.
Cutting Dies
Cutting dies are used to cut the metal. They use cutting and shearing action
for cutting the metal. Examples of cutting dies are blanking dies, piercing
dies, perforating dies, notching dies, trimming dies, shaving dies and nibbling
dies, etc.
Forming Dies
Forming dies change the shape of the blank without removing any stock.
Example of forming dies are drawing dies, bending dies and squeezing dies.
According to the method of operation, dies are classified as simple dies,
compound dies, combination dies, progressive dies, transfer dies and steel
rule dies, etc.
 Die Classifications
Number of stations
Single station dies
Multi-station dies----progressive dies
Single station dies may be :
Combination (a die in which both cutting and
noncutting operations are accomplished at one
press stroke) or
Compound (a die in which two or more cutting
operations are accomplished at every press
stroke).
 Compound Dies
In these dies, two or more operations may be performed at one
station.
Such dies are considered as cutting tools since, only cutting
operations are carried out.
Figure shows a simple compound die in which a washer is made by
one stroke of the press.
The washer is produced by simple blanking and piercing operations.
Compound dies are more accurate and economical in production as
compared to single operation dies.
 Combination Dies
In this die also , more than one operation
may be performed at one station. It is
different from compound die.
In this die, a cutting operation is combined
with a bending or drawing operation, due
to that it is called combination die.
 Progressive Dies
A progressive or follow on die has a series of operations. At
each station , an operation is performed on a work piece
during a stroke of the press.
Between stroke the piece in the metal strip is transferred to
the next station. A finished work piece is made at each
stroke of the press.
While the piercing punch cuts a hole in the stroke , the
blanking punch blanks out a portion of the metal in which a
hole had been pierced at a previous station. Thus after the
first stroke , when only a hole will be punched , each stroke
of the press produces a finished washer.
Progressive dies are made with two or more stations arranged in
a sequence.
Each station performs an operation on the workpiece, or provides
an idler station, so that the workpiece is completed when the
last operation has been accomplished.
Thereafter each stroke of the ram produces a finished part.
Thus after the fourth stroke of a four station die, each
successive stroke will produce a finished part. Operations
which may be carried out in a progressive die are piercing,
blanking, forming, drawing, cut off, etc. The list of possible
operations is long.
The number and types of operations which may be performed in a
progressive die depends upon the ingenuity of the designer.
Fig shows a four station progressive die. The die block is made
up of four pieces and fastened to the die shoe.
This permits easy replacement of broken or worn die blocks. The
stock is fed from the right and registers against a finger strop
(not shown). The first stroke of the press Fig produces a
square hole and two notches.
These notches form the left end of the first piece.
During the upstroke of ram, the stock is moved to the next station
against a finger stop (not shown). The stock is positioned for
the second stroke. The second station is an idler, Fig . The right
end of the first piece, the left end of the second piece, and a
second square hole are pierced.
 Press Tool Components
The press tool components may be divided into following types:
Working components, which participate in shaping of parts: dies, punches,
and their sections.
Structural components which serve for joining the working components to one
another and to press: upper shoe (punch holder), lower shoe (die holder) and
shanks.
2. Basic die components

Die with guide plate

2. Basic die components
Guiding components, which ensure accurate alignment of the
upper shoe with the die shoe in operation: guide posts and
bushings.
Feeding components, which feed the stock strip or blanks to the
stamping station.
Locating and locking components, which provide for an
accurate positioning of the stock or blank in the die and fix it in
place while the operation is performed.
Stripping components which strip and remove the blanks and
scrap from the working after the position is over: strippers, push off
pins, knockouts.
Fastening components which join and hold together all parts and
units of the press tool: punch plates, die blocks, and cases and all
fasteners.
 Punch
Lower end of the ram holds punch holder which is equipped with the punch plate. Punch plate is generally made of
stainless steel or HSS. The punch plate holds the punch rigidly and accurately. Different ways of holding the punch
are described below :
(a) Punch can be fastened by forcing it to punch plate, top end of the punch is flattened to fit in the countersunk
recess as shown in Figure 3.5.
(b) Punch can be clamped to the punch plate by a set screw. The correct position of the punch is located by cutting
a slot into the punch plate as shown in Figure 3.5.
(c) Shank of the punch is forced into the punch plate top end of the punch is made flat to fit into the countersunk
recess as shown in Figure 3.5.
(d) Punch can be tightly secured to the punch plate with the help of grubs screws as shown in Figure 3.5.
(e) Set screws are used to fastened the punch to the punch plate as shown in Figure 3.5.
(f) Fastening of punch with the help of a set screw and it is located during fastening with the help of two dowel pins
shown in Figure 3.5.
(g) Flange end of the punch is secured to the punch plate by set screws from the punch end as shown in Figure
3.5.
 DIE SET AND ITS DETAILS
The complete die set consists of a punch, die and some other
accessories. Perfect alignment of punch and die is most important
for satisfactory working of punch. Accessories of die set provides
the require alignment and rigidity to the system and improves
accuracy of the system performance. The die accessories are
shown in Figure.
 Punch Holder
It is also known by its other name upper shoe of
die set. Punch holder is clamped to the ram of
press. It holds the punch below it.
Punch
It is the main tool of die assembly which directly
comes in contact of workpiece during its
processing.
Die Holder
It is also called die shoe. Its work as a support for the die block and it is rigidly fastened to the balster
plate of the press.
Stops
Stops are used for maintaining correct spacing of the sheet metal when it is fed below the punch to
maintain the quality of output. These restrict the feed of stock (workpiece) to a pre-determined length
each time without doing any precise measurements. Normally two types of stops are used bottom stop
and lever stop as described below. .
Bottom Stop
Bottom stop is a type of mechanical mechanism. This mechanism stops
the movement of punch after end of each cut. A button is located in such
a manner when fresh stock is fed to die, the button is pressed due to the
impact of the fed stock, indicating feeding of true length of the stock.
This way the mechanism also acts as a fixture. Pressing of button
enables the system ready for next cutting action. The button stop is used
in hand presses and in slow acting power presses.
Lever Stop
This mechanism operates with the help of a lever. After the completion
of one cut, the stop mechanism stops the downwards movement of
punch for next cut when fresh stock is fed it is stopped by a lever after
feeding it up to certain length. The lever also enables the punch to move
for cut.
 Strippers

Stripper is used to discard the workpiece out side the press after the
completion of cutting or forming operation. After the cutting when
punch follows upward stroke the blank is stripped off from the punch
cutting edge and prevents it from being lifted along with the punch.
This action of prevention is performed by the stripper.
Knockouts
Knockout is also a type of stripper which is used generally in case of
inverted dies. After the completion of cutting action, the blank is ejected
by the knockout plate out of cutting edge.
Pressure Pads
Pressure pads are plates which grip the workpiece very tightly at the
ends when it plastically flows between the punch and the die. This tight
griping eliminates the chances of wrinkling in the process of metal
forming. A spring loaded plunger acting on the bottom of workpiece
plate also serve the same function. The pressure pads do a type of
ironing on the sheet metal workpiece
 Guide Posts
Accurate alignment between die opening and punch
movement is very important. Guide posts are used for
correct alignment of punch and die shoe.
Punch Plate
Punch plate is also known as punch retainer. This is
fixed to the punch holder. Punch plate serves as a guide
way to hold the punch in right position and properly
aligned. This makes the replacement of punch quick and
correct.
 Backing Plate
Backing plate is used to distribute pressure uniformly over
the whole area (maintains uniform stress), it prevents the
stress concentration on any portion of punch holder. This is
generally made of hardened steel inserted between the
punch and punch holder.
Die Retainer
The purpose of die retainer is same that is of punch plate
and punch holder. Die retainer is fixed to the bed (base) of
the press to hold the die block in correct alignment with the
movement of punch. In some specific cases die shoe itself
works as a die retainer
 METHODS OF DIE SUPPORTING
Die is normally held in die holder which is clamped to the balster
plate mounted on the table or base of the press. Three different
methods of securing die blocks to the die holder .
Design of Die
 Design of Blanking die
1) Strip layout
In the design of blanking die the first step is to prepare
blanking layout, that is, to layout the position of the
workpieces in the strip and their orientation with
respect to one another.
While doing so, the major consideration is the
economy of material.
Another important consideration in strip layout is
the distance between the blanks and the strip edge
and
distance between blank to blank. The distance must
increase with material thickness.
A general rule of thumb is to keep this distance
equal to 1 to 1.5times the material thickness.
The following figure is example of strip layouts.
A Front scrap
B Bridge thickness
(space between parts and strip edge,and
part to parts)
C the distance from a point on one part
to the corresponding point on the next
part.
H Part width
l - Length of part
W Width of strip
Y Scrap recovery at end
N Number of blanks
t thickness of strip
L Length of strip

B= 1.25t, when C is less than 2inch

= 1.5t, when C is more than 2inch
C=l+B
W = H + 2B
A = t + 0.015H
Y =L Nc +B
N = L B /C
 Die block
The die block is the part of the two mating tools which carry
the cutting edges.
It is subjected to extreme pressure and wear conditions.
Hence the die block is made of superior quality
of tool steel.
Sectional dies are made of accurately ground matching
components which may be assembled together easily.
Generally high carbon, high chromium steels are used
for die sections which are
hardened and ground.
 Die block thickness
The minimum thickness of the die block depends up on the
strength required to resist the cutting forces, and it will depend
up on the type and thickness of the material being cut.
The determination of die block thickness depends up on
experience and thumb rules.
According to the Rule of thumb, the die thickness may be
obtained as follows:
Die thickness=19mm, for blank perimeter >=75mm
Die thickness=25mm, for blank perimeter = 75mm to 250 mm
Die thickness=31mm, for blank perimeter>250mm
This rule of thumb is for die blocks made of tool steel.
 The die thickness can also be selected from:
Stock Production quantity (million)
thickness in 5 25 50 100 500 unlimited
mm

0.375 9.375 12.5 15.62 19 25 28 Die

0.775 12.5 15.625 5 25 28 28 block
2.325 15.625 19 19 28 31 34 thickn
3.125 19 25 25 31 31 34 ess
4.675 25 28 28 31 34 37.5 In
6.25 31 31 28 34 37.5 37.5 mm
31
 Die opening
The side walls of the die block opening should be provided with sufficient relief and
taper so that the blank drops clear through.
Taper can either start from the top surface itself or after a straight land from the surface
of the die.
Soft material such as copper, brass and aluminium tend to swell more rapidly after
being cut.
This may be due to a slight spring back or return of the material along the lines in
which it has been stressed in compression, hence for such metals the die cavity must
be fully tapered.
But for steel, the taper or relief should start after the straight land from the die surface.
The straight land should be at least equal to stock thickness and not less than 3 mm.
The relief angle or taper may be taken as to 1 degree for small dies, 1 to 2
degrees for average dies and 2 to 3 degrees on large dies.
 Fastening of die block
The die blocks is secured either to the die shoe or press
plate.
The size of the screws and bolts employed is usually not
calculated.
According to one empirical rule:
Screw = 0.5 t, for t <=19 mm.
= 0.4 t, for t >19 mm.
Along with screws, dowel pins are also used for alignment
purposes.
They are usually located near diagonally opposite corners of
the die block, for maximum locating effect.
The diameter of the dowel pins is taken to be equal to the
outside diameter of the fastening screws.
 Dowel pins
Any misalignment of die components may cause severe
damage.
Therefore, any component that must be located
accurately are held in such position by dowels.
 Two dowels are necessary for one component to achieve complete
location.
They are press fitted in the component and the mounting plate or shoe.
Keeping the dowel diameters same as that of the screws facilitates the
drilling and reaming of dowel holes.
The position of the dowel pins is so selected as to make through holes
for them; otherwise the removal of the pins during disassembly will be
too difficult.
The effective thread depth of the screws should be 1.5 to 2 times
the screw diameter.
 Stripper and Stock Guide
After blank has been cut by the punch on its downwards stroke the
scrap strip has the tendency to expand. On the return stroke of the
punch, the scrap strip adheres to the punch and is lifted up. This
action interferes with the feeding of the stock through the die and
some device must be used to strip the scrap material from the
punch as it clears up the die block. Such a device is called stripper
or stripper plate.
The function of stock guide is to guide the stock through various
stations. The strippers are classified into two types: channel or box
stripper and spring operated stripper or pressure pad.
 An opening is cut through the stripper plate for free passage of the punch.
By the rule of thumb, this opening can be about 1.6 mm larger than the
blank size on all sides. The thickness of stripper can be taken from 10 to16
mm. the following empirical equation may be used to obtain thickness of
stripper.
ts= 1/8 (w/3 + 16t)
Where w and t are width and thickness of stock strip and ts is stripper plate
thickness. The under side of the stripper which comes in contact with the
strip should be machined and ground. The height of the stock strip channel
should be at least equal to 1.5 times the stock thickness. The width of
channel should be equal to the width of the stock plus adequate clearance.
The material for channel stripper is generally cold rolled mild steel.
The disadvantages of this stripper are that it hides the work from the
operator and it would interfere with removal of the scrap in large blanking
operation.
 Punch
The punch must be perfect mate to the die block opening to ensure
complete shearing of the blank.
The punch length must also provide for the anticipated number of
regrinds.
The maximum length of the punch can be calculated from the
formula:
L = (d/8*[(E/Ts) x (d/t)]1/2
Where E is the modulus of elasticity.
Punches are made of good grade tool steel, hardened and
ground. The hardness recommended is Rockwell C 60.
Punches with unguided length of more than 100 mm are avoided.
A sharpening allowance of 6 to 12.5 mm is provided in punch length.
 Backup plate
For small punches, back up plates or pressure plates are often provided between the punch plate and punch holder.
The punch plate or punch retainer fits closely over the body of the punch and holds it in proper relative position.
The backup plate is provided to take the cutting forces of the punch head, provide a base when punch does not have a flange
or shoulder and prevent the hardened punch from being pushed into the softer punch holder, thus becoming loose.
The main criteria whether a backup plate should be provided or not is the unit of compressive stress on the punch, given as,
p = F/A
where A is the area of the punch.
For straight punches p = F/(/4)d2
For punches with shoulder p = 4tTs.d1/d22
For punches with shoulder p = 4tTs.d1/d23
 Backup plate is provided if p exceeds 245 N/mm 2.
As a rule backup plate is used whenever the punch diameter is less than
four times the stock thickness.
The thickness of backup plate depends up on the stock thickness.
For stock thickness up to 2 mm, the thickness of back up plate should be
about 3 mm and for thicker stock, it should be about 6mm.
 Methods of holding punch
The mounting or securing of a blanking punch in the
punch holder is an important issue.
Being relatively bigger, they are made with flanges that
are doweled into position and directly fastened to the
punch holder by screws without the use of punch plates
and sometimes without back up plate.
When used the thickness of the punch plate should be
1.5 times the punch diameter.
 Die-set
The die shoe, the punch holder together with two or more guide
posts constitute a die set.
The die shoe and the punch holder are made of C.I, C.S and rolled
steel.
For smaller dies, C.I is used whereas, for larger and special die sets
C.S and rolled steel are used.
Bushings are assembled to the upper shoe by press fitting and
guide posts are press fitted into the lower shoe.
The bushings and posts are sized to provide a slip fit.
For average range of die sets, the diameter of the guide posts
varies from 2.5 cm to 7.5 cm.
Larger pins may be used if extreme alignment is required.
Dimensions of the die set
Dimensions are in cm.
Die area Die holder Thickness Min guide
diameter post dia.
Rectangular Dia. Die Punch
holder holder
4.45x 8.90 7 12.7 4.45 3.18 1.27
5.72x11.44 8.9 15.25 4.45 3.18 1.60
7 x 14 10.2 17.80 5.00 3.80 1.90
8.9 x 17.8 13.35 22.90 5.00 3.80 2.55
11.45x22.90 17.80 27.95 5.00 3.80 2.85
 Bolster plate
When many dies are to run in the same press at different times, the wear
occurs on the press bed is high.
The bolster plate is incorporated to overcome this problem.
M.S. plate (2.5 to 7.5 cm) made from boiler plate is used.
It is attached to the press bed and the die shoe is then attached to it.
It is machined so that its surfaces are flat and parallel.
Bolster plates are relatively cheap and easy to replace.
The other functions of bolster plate:
To provide attachment holes for the dies rather than drilling these holes in
the press bed.
To support the die shoe when it is located over a large hole in the press bed.
To take up space in the press when the press shut height is too great for the
die shut height.
To provide chutes for ejecting parts or scrap out the sides of the press.
 Forging Dies
 Forging Processes
Forging is a manufacturing process involving the
shaping of metal using localized compressive forces.
Forging can produce a piece that is stronger than an
equivalent cast or machined part. As the metal is shaped
during the forging process, its internal grain deforms to
follow the general shape of the part. As a result, the grain
is continuous throughout the part, giving rise to a piece
with improved strength characteristics.
There are multiple options for metal deformation using the
forging concept. The two most common processes are
open and closed die forging.
While similar in the basic idea of using pressure and
temperature to modify material, the two types of forging are
made distinct by their use of dies to form the metal.
 Drop forging
Drop forging is a forging process where a
hammer is raised and then "dropped" onto the
workpiece to deform it according to the shape
of the die.
There are two types of drop forging: open-die
drop forging and closed-die drop forging. As
the names imply, the difference is in the
shape of the die, with the former not fully
enclosing the workpiece, while the latter does.
 Open Die Forging
Open die forging is the process of deforming a piece of metal between
multiple dies that do not completely enclose the material.
The shape of the metal is altered as the dies hammer or stamp the
material through a series of movements until the desired shape is achieved.
Products formed through open forging often need secondary machining
and refining to achieve the tolerances required for the finished specifications.
Open die forging is often used for short run forgings of parts that are
simple, rather than complex, in design, such as discs, rings, sleeves,
cylinders and shafts.
Custom shapes can also be produced with open die forging. The repeated
working of the material through the deformation process increases the
strength of the grain structure.
Some additional benefits of open die forging include improved fatigue
resistance and strength. Open die forging also reduces voids.
 The above image "Fig 1" is showing notching, this process uses a tool
similar in shape to a chisel, the operator will rotate the work piece
through a gradual 360 ensuring the tool leaves an even impression
around the circumference of the work piece. The operator may have to
rotate the work piece several times to achieve the desired shape.

For "Fig 2" multiple sided shapes can be made with much the same
method as notching, just with different tools, for shapes where more
accuracy is required for example the six sided shape above a machine
jaw might be used to hold the work piece in place and move it through
a consistent rotation of degrees each tool impact.

Open die drop forging is capable of producing forgings from

around 2kg to 150 tons and when a very large structurally sound
part is required open die forging is usually top choice
Applications of open die forging
MARKETS
Markets
Ellwood City Forge is a leading
supplier of open-die forgings for the
most demanding applications. We
service multiple industries including:

Oil & Gas

Power Generation
Mining
Industrial Machinery
Metal Processing
Power Transmission & Gearing
Aerospace
Infrastructure & Construction
Defence
Shipbuilding
 Closed Die Forging
Closed die forging (also referred to as impression die forging) is a metal
deformation process that uses pressure to compress a piece of metal to fill
an enclosed die impression. In some closed die forging processes, a
succession of impression dies are used to modify the shape of the material
into the final desired shape and form. The type of material, tightness of
tolerances, and need for heat treatment can determine the number of
passes the product requires through the dies.
There are two types of equipment that are commonly used for closed die
forging: mechanical forging presses and hydraulic forging presses.
Mechanical forging presses: Manufacturers use mechanical presses for
high volume product runs.
Hydraulic forging presses: These presses are useful for more complex
shapes.
Drop forging: This process is economical for large runs and is often used
instead of casting because of its superior internal grain structure.
Fig. : Stages of closed die forging process
 Processes or phases in the
forging die
The processes in the forging die can be
split into three phases
1. Upsetting
2. Lateral flow
3. Vertical flow (rise)
 A simple type of open die forging is called upsetting. In
an upsetting process the work is placed between two flat
die and its height is decreased by compressive forces
exerted between the two die.
Since the volume of a metal will remain constant
throughout its deformation, a reduction in height will be
accompanied by an increase in width.
Figure shows a flat die upsetting process, under ideal
conditions.
 Lateral flow
Lateral flow is when the material flow is
mainly transverse to the movement of the
die. The flow paths where the material
touches the walls of the die are relatively
long. Because of this, a lot of friction
occurs and high deformation forces are
required.
 Vertical flow
The vertical flow of the material is the last forging phase in the die.
Here, the flow of the material is in the opposite direction to the
forging motion. The initial height of the workpiece is raised in places.
However, in order for vertical flow to occur in the die to begin with,
the resistance to flow in the flash gap must be higher than that
required for vertical flow in the die. The material must not flow into
the flash gap until the die cavity is completely filled. This resistance
to flow in the flash gap depends upon the ratio of flash land width to
flash land height (w/s).
 Forging nomenclature
Various terminologies are used for geometric shapes on an impression-die
forging based on the direction in which metal must flow to fill the die
impressions.
When a wall is filled by the flow parallel to die motion is called a rib, and the
projection made by filling parallel to the die motion is called a boss.
A web is formed when the wall is filled by horizontal flow, perpendicular to
die motion and parallel to the parting plane. A small web area surrounded by
thicker metal is called recess. Figure illustrates these terminologies.
 Design recommendations
The general rules for designing impression-die forgings may be
summed up as follows:
Construct as simple shapes as possible and consider the question
of materials in their design.
Avoid sharp corners and abrupt transitions in the cross-section.
When designing the shape, consider how it can be gripped for
mechanical processing.
Consider whether complicated forms can be produced more easily
using other manufacturing processes.
As well as these rules, when designing forgings dies, the following
points in particular should be taken into account
 Parting line: When the die halves join together and confine
metal in their cavities, the joining line of the die halves around the
edge of the forging surface is called parting line of the forging.
Under ideal condition, the parting line should lie on plane
perpendicular to the axis of the die motion, as shown in Figure
M4.7.4
Sometimes the impression is entirely on one half and the other die half
is completely flat and the line surrounds the largest projected area of
the piece as shown in Figure M4.7.5.

Figure M4.7.5: Parting line is in one plane perpendicular to die motion,

and the complete impression is in one die half
 Die block dimensions
The dimensions selected for the die block depend on the
depth of the cavity.
Minimum block dimensions

 Draft: Die impressions are generally made tapered for easy

withdrawal of the forgings from their dies.
In fact, forged surfaces that generally lie parallel to die motion are
correspondingly tapered.
The taper provided is called draft. Table shows typical
standard draft angle ranges for finished forgings in the various
alloy families. Often certain shapes exhibit natural draft. If
cylindrical section needs to be considered, the draft angle has to be
modified slightly to provide draft in the narrow region next to the
parting line as shown in Figure.
 Ribs, Bosses, Webs, and
Recesses
It is recommended to avoid too high and narrow ribs and
bosses for easy metal flow.
This is shown in the Figure, It becomes very difficult when large
amounts of metal has to be moved out of relatively thin webs into
such projections as deep ribs and high bosses.
Hence, it is better to taper such webs toward the ribs and bosses.
In addition, deep recesses are also found to be easier to forge provided
they have spherical bottoms.
Suitable materials for forging
Most of the metals and alloys can be forged at
elevated temperatures and forgeability is the term
used to measure this behavior.
Forgeability refers to the ease with which the metal
deforms plastically.
Table M4.7.1 summarizes the relative forgeability (in
decreasing order) of metals and their alloys.
Suitable materials for forging are the alloys of
aluminum, magnesium, copper, and mild steels.