Design for Manufacture

(Course Code:18ME731)

Department of Mechanical Engineering

JSS Academy of Technical Education, Bangalore-560060
 TEXT BOOKS

Design for Manufacture by Harry Peck, Pitman publishing, 1983

 Learning objectives

• Factors to be considered while designing parts with focus on manufacturability.

• Through understanding of GD & T techniques in manufacture.

• Design considerations for designing components produced using various

machining operations.

• Design rules and recommendations for processes like casting, welding, forgings

powder metallurgy and injection moulding.

DFM

Module 5
Design of components with Forging Consideration
Introduction Forging

• Forging is the controlled plastic deformation of a metal piece into a shape,

usually at an elevated temperature.

• Pressure or press may be used.

• The final part geometry is depending on the profile.

• This process refines grain structure and improve physical properties.

Introduction Forging

Forging is a bulk deformation processes in which a solid billet is forced under high

pressure by the use of a press to undergo extensive plastic deformation into a final

near-to-finished shape.

Examples of deformation processes are;

Extrusion: a long object is produced by pushing a metal billet through a die.

Drawing: a billet is pulled through a die.

Rolling: a slab is passed through rolls to make a thin sheet.

Introduction Forging

Fig.: Bulk deformation processes that convert cast metals into semi fabricated or finished products.
 Introduction Forging

• Forging usually is carried out on a hot workpiece, but other deformation

processes like cold extrusion or impact extrusion may be conducted cold,
depending upon the material.
• Due to extensive plastic deformation, the metal undergo metallurgical changes.
• Any porosity is closed up, and the grain structure and second phases are
deformed and elongated in the principal directions of working, creating a “fiber
structure.”

The redistribution of the fiber structure direction during the forging of a part
Introduction

Types of forging machines

Introduction
Any material (Metal or Alloy) which can be brought to the plastic stage through heating can be forged.

Hot forging temperature range for different metals and alloys

Characteristics Forging

• Controlled grain structure

• Proper design enables the alignment of grain flow with directions of the principal

stresses that will occur when the part is loaded in service.

• Grain flow is in the directional pattern that metal crystals assume during plastic

deformation rather than random orientation.

• Strength, ductility, and impact resistance along the grain are significantly higher.

• Forging ensure structural integrity.

• Internal pockets, voids, inclusions, laps, and similar flaws are easier to avoid
 Forging
Properties

• Strength, Malleability, Resistance to fatigue, Durability, shock/bending

resistance, Machinability.
 Forging
Applications

• Structural components in Aerospace & Automotive industry (High-strength & light-

weight requirements).

• Moving parts are forged to reduce inertia forces.

• Parts that must be supported by other structures are forged to reduce overall weight

and complexity.

• Hand tools that people lift and handle are forged to reduce weight.

• Parts whose failure would cause injury or expensive damage are forged for safety.

• Decorative parts, even when stressed very lightly, may be produced from forgings.
Applications Forging

• Landing gear parts for aircraft

• Automotive connecting rods
• Universal joints
• Crankshafts
• Off-highway and farm equipment parts
• Plumbing valves, Tees, Elbows
• Railroad wheels, axles
• Gears
• Turbine disks and blades
• Bearing assemblies
 Forging

Fig. Forging produces parts with an unbroken grain flow following the contour of the
part.
 Forging

A collection of typical forgings

 Forging Nomenclature Forging

• Any wall filled by flow parallel to die motion is a rib, and projection is called a
boss.
• The wall filled by horizontal flow, perpendicular to die motion and parallel to the
parting plane, is the web.
• A recess is a small web area surrounded by thicker metal.
Types of Forging Processes Forging

1. Open-die
Blocker forgings
2. Closed-die forging
Precision forgings

Open-die forging

Closed-die forging
Types of Forging Processes Forging

Blocker forgings
Closed-die forging
Precision forgings

Blocker forgings

• Blocker forgings have thicker sections and generous radii, easier to form, fewer

forming stages and lower loads.

• Used when small quantities of parts are required, reduced die costs, or difficult-to-

form materials, Hard to obtain thin sections.

• Require more subsequent machining to reach the final shape.

Types of Forging Processes Forging

Blocker forgings
Closed-die forging
Precision forgings

Precision forgings

• Precision forgings are parts formed with thinner sections and close

tolerances, nearer to net shape.

• Precision forgings are more often produced in light alloys (Aluminum alloys,

magnesium alloys, etc.)

Forging Allowances Forging

Forging allowances for finish machining and draft

 Forging Allowances Forging

• Machining allowance: Addition to any dimensional

tolerances.
• Must be sufficient to finish the surface by machining.
• The machining allowance depends on several factors,
particularly on the amount of oxidation that results from
heating the part up to the forging temperature.

• Draft is an angle allowance added to surfaces parallel to the

direction of die closure to facilitate release of the part from the

Forging allowances for finish machining and draft

die.
• In general, draft allowances on inside surfaces are greater than
those on outside surfaces, as the part to shrink onto projections
in the die as cooling starts.
 Forging Allowances Forging

• All edges and corners in the part must have radii

• These radii are necessary to aid material flow and
ensure good die filling.
• In addition, sharp corners in dies leads to premature die
failure due to fracture, as a result of associated stress
concentrations.
• In general, larger radii are recommended for the more
Forging allowances for finish machining and draft
difficult to forge materials.
Forging Allowances Forging
Forging Allowances Forging
 DFM Guidelines for Impression / Closed - Die Forging

1. All features should be oriented so that they can be formed in closed die moving

in opposite directions, as the part shown in Fig.

2. Features like undercuts and holes oriented other than in the direction of forging

are not typically forged and must be fully machined.

• The most economical shape to forge can be formed in closed die moving in opposite directions.
 DFM Guidelines for Impression / Closed - Die Forging

3. Forging cost is minimized and tolerances reduced when forging loads are
balanced, eliminating side loads on the machine members that restrain the dies

• The forging as oriented generates a side

• The forging can be rotated in the die to balance the lateral
thrust in the die requiring counter lock to
loads and eliminate the counter lock.
prevent lateral shift of the die.
• Holes in the bosses cannot be forged, must be fully
• The counter lock is subject to wear from
machined.
the side loads.
 DFM Guidelines for Impression / Closed - Die Forging

3. Forging cost is minimized and tolerances reduced when forging loads are
balanced, eliminating side loads on the machine members that restrain the dies

• The forgings can be oriented opposite to balance the side loads.

• This arrangement permits the holes in the bosses to be forged to reduce the amount of

machining required.
 DFM Guidelines for Impression / Closed - Die Forging

4. Interior corner (fillet) radii are dependent on forging severity (primarily rib height)
and the forgeability of the alloy

Representative Fillet and Corner Radii for Forgings with 25 mm (1.0 in.) High Ribs
 DFM Guidelines for Impression / Closed - Die Forging

5. Sharp exterior corners require high forging pressures to fill the corresponding die

features.

• Sharp interior corners (fillets) cause difficulties in metal flow, may require one or

more preform dies to attain, or may require additional machining operations.

• Radii should be as large as possible consistent with functional and assembly

constraints.

• Corner and edge radii should also be uniform to minimize die sinking cost.
 DFM Guidelines for Impression / Closed - Die Forging

6. Draft angles should be the maximum allowable, consistent with functional,

assembly and weight constraints.

• For ferrous forgings, draft angles less than 5° usually prohibit the use of

hammers.

• Dies installed in presses are usually equipped with knock-out pins to eject the

forging from the cavity, and can produce forgings with little or no draft.
 DFM Guidelines for Impression / Closed - Die Forging

7. As a general rule, less draft is required on the outside of a feature than on the
inside.
 DFM Guidelines for Impression / Closed - Die Forging

8. Component features that are held to close tolerances should be formed in the

same die member to avoid additional cross-die tolerance.

9. All datum targets and tooling points should be located on features made in the

same die half. The upper die half is preferred since there is less contact between

the die and the forging, and consequently less cooling.

End of Module