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Impression-Die Forging (Cont'd) : - F K Y A

Impression die forging involves applying force gradually at first, then rapidly when flash forms, with a final steep force to achieve complete filling. The force is calculated using factors like the projected area and flow stress. Closed die forging creates parts without flash using precise control of parameters for near net shape parts. Defects in forging can include cracking, buckling, and incomplete filling from improper forging technique or die design.

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thacal
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123 views

Impression-Die Forging (Cont'd) : - F K Y A

Impression die forging involves applying force gradually at first, then rapidly when flash forms, with a final steep force to achieve complete filling. The force is calculated using factors like the projected area and flow stress. Closed die forging creates parts without flash using precise control of parameters for near net shape parts. Defects in forging can include cracking, buckling, and incomplete filling from improper forging technique or die design.

Uploaded by

thacal
Copyright
© Attribution Non-Commercial (BY-NC)
Available Formats
Download as PPT, PDF, TXT or read online on Scribd
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Impression-Die Forging (cont’d)

• F=KpYfA
– Kp – presure multiplying factor
• Simple shapes (without flash): 3-5
• Simple shapes (with flash): 5-8
• Complex shapes (with flash): 8-12
– Yf – flow stress for strain rate
– A – projected area
• Force increases gradually at first
• Force increases rapidly when flash forms
• Final steep force is applied to achieve
complete filling
• http://www.mscsoftware.com.au/products/software/msc/superforge/
Closed Die Forging
• Forging created without flash
• Proper volume of die is required
• Precise control of parameters
• Near net shape forging
• Very precise machines
• Special die designs
• Aluminum, magnesium, etc.
Isothermal Forging
• (Hot die forging)
• Die heated to temperature of forging
• Good dimensional accuracy
• Die is made of nickel alloy
Coining operation
• Force or pressure applied is 5 to 6 times the
flow stress of the material
Heading
• Upsetting operation at the end of the rod
• Can be done in highly automatic machines
called Headers.
• Piercing
– We can create holes or cavities on a part
• Hubbing
– A hardened puch with a particular tip geometry
is pressed into the surface of a blcok. Produce
a die cavity
• Cogging
– Progressive pressing of a arge part
Die Allowances
• Shrinkage allowances
• Machining allowances
• Work holding allowance
• Material Used
– Tool Steel, Die steel
– High carbon alloy steel (Cr, Ni, vanadium)
– Hardness: Rc=45-60
• Material should have strength, toughness, at
high temp.
• Hardenability, mechanical and thermal
shock resistance, wear resistance
• Dies are the most critical part of the forging
operation
– Proper fillet radius should be provided
– Draft angle for all vertical faces for ease of
removal
– Flash should be allowed to form
– Flash = 3% of max. thickness
– C=15% of this
Roll forging
• Cross sectional area of a bar is reduced and
altered in shape by passing through a pair of
rollers.
– Tapers shaft
– Pre stages of a crank shaft
• Skew rolling
– Used for making ball bearings
Type of Forging Process
• Hydraulic press:
– Constant low speed
– Ram speed can be varied
– Large amount of energy can be applied (75,000
tons)
• Mechanical Press
– Usually uses crank or eccentric
– Force depends on the stroke position
– Proper setting of the position is important
– 12,000 tons
• Screw Press
– Energy from flywheel
– Load transmitted through vertical screw
– High precision path
– Extremely accurate alignment top and bottom
halves
– 32,000 tons
• Hammers
– Potential energy of the ram
– Speed can be high
– Sometimes steam or air is used to aid the die
– Multiple blows may be needed
• Selection of Press depends on
– Precision
– Strain rate sensitivity
– Amount of deformation
– Size of forging
– Production rate
• Metal flows in the direction of least
resistance
• Distribute material so that it can properly
fill die cavity
• Several “Intermediate stage” Dies are used
for obtaining final forging
– E.G. connecting rod, crankshaft
Defects in Forging
• Fatigue resistance is reduced
• Corrosion, stress raisers
• In complete metal for machining
• Mismatch of halves of the pierce
• Poor strength in the direction of principle
stresses
Anisotropic Behavior
• Not always considered as a defect
• Metal flows in different directions
• Thus we obtain different strength at
different points of a forging
Effect of corner radii
• Metal flows better as a larger radius than in
a smaller radius
• For smaller radius, the metal can fold over
itself to cause “cold shuts”
Defects
• Surface cracking
– Improper temperature, strain rate, design of dies
• Buckling
– Lap formation can occur – importance of forming
distribution
– Solution – increase the thickness of the part
• Internal Defects
– Improper filling of the die
– Larger than required billet can cause it
http://www.transvalor.com/forge2/demo1.htm
Grain Flow Pattern
• Grains flow is exposed: end grains
• Can be avoided by intermediate steps in
forging and proper orientation of
workpieces
– Stress raiser
– Corrosion, etc.
Summary
• True Strain/True Stress, Strain rate, strain rate sensitivity
• Forging – Forces involved in rectangular and cylindrical
work pieces
• Different types of forging – open, closed, impression etc
– Multi stage forging
• Cogging, coining etc
• Roll forging
• Types of presses
• Defects

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