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    Forging Lab

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    Forging Lab

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    7jmfwksw5c
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    Download as pptx, pdf, or txt
    18 views16 pages

    Forging Lab

    Uploaded by

    7jmfwksw5c

    Copyright:

    © All Rights Reserved
    Download as PPTX, PDF, TXT or read online from Scribd
    Download as pptx, pdf, or txt
    of 16

    ME-105 Workshop Practice

    FORGING
    • What is Forging ?
    Forging is the manufacturing process ,involving the shaping of metals
    using localized Compression forces .
    • Types of Forging
    •
    • Cold Forging & Hot Forging

    • 1. COLD FORGING
    • The cold forging is performed at room temperature. The job-piece is compressed between
    two dies until it has assumed their shape.
    • Advantages of Cold forging
    • Very little or no finishing work is required in Cold forged, which saves cost.
    • High precision.
    • Economical
    • High production rates
    • Long die life
    • Cold Forging Disadvantages
    • Only simple shapes in high volumes can be shaped
    • Not suitable for customized components
    • Low ductility
    • 2. Hot Forging
    • Hot forging process is performed at extreme high temperature (up
    to 1100°C for steel, 360°C to 520°C for Al-alloys, 700°C to 800°C for
    Cu-alloys). These temperatures are necessary in order to avoid
    strain hardening of the metal during deformation.
    • Hot Forging Advantages
    • Good ductility
    • More flexible than cold forging, thus customized parts can be
    manufactured.
    • Excellent surface quality
    • Hot Forging Disadvantages
    • Less precise dimensional tolerance.
    • Careful monitored cooling process to be performed
    • Risk of warpage
    • Risk of job piece and atmosphere reactions
    • Basic Categories of Forging
    • OPEN –Die Forging
    • IMPRESSION –Die Forging
    • CLOSED-Die Forging
    OPEN DIE FORGING CLOSED DIE FORGING
    Advantages
    Better fatigue resistance and improved microstructure The internal grain structure formation increases the tightness
    and strength of the products.

    Continuous grain flow and finer grain size Economic for large production runs.

    Increased strength and longer part life No material limitation

    Less material waste Better surface finish

    Reduced chance of voids Less or no machining required for its close tolerances

    Dimensions of tighter tolerances and net shapes can be


    Valuable cost savings achieved

    Disadvantages
    It is not capable of forming close tolerance and higher It is not very economical for short runs due to the high cost of
    precision parts die production

    Machining is often required to achieve desired dimensions Closed die forging presents a dangerous working environment
    • Forging Methods .

    • Smith Forging or Hand Forging

    • Drop Forging

    • Press Forging

    • Machine forging or Upset forging


    SMITH FORGING or HAMMER FORGING
    • This is the traditional forging operation done
    openly or in-openly dies by the village black
    smith or modern shop floor by manual
    hammering or by the power hammer.

    • The process involves heating the stock in the


    black smith hearth and then beating it over
    the anvil. To get the desire shape the operator
    has to manipulate the component in between
    the blows.

    • The types of operation available are fullering,


    flattering, bending , upsetting and swaging
    • Different Forging Operations

    1. Upsetting

    • The thickness of the work reduces and length increases


    • Different Forging Operations
    2. Fullering
    • The cross sectional area of the work reduces as metal
    flows outward, away from center.
    • Different Forging Operations
    3. Drawing
    • The cross sectional area of the work is reduced with
    corresponding increase in length using convex dies.
    • Different Forging Operations
    4. Swaging
    The cross sectional area of the bar is reduced using concave
    dies
    LAB Task : Making a Chisel by Forging

    Chisel: A cutting tool consisting of a slim oblong


    block of metal with a sharp wedge or bevel
    formed at one end .

    It may be provided with a handle at the other end


    .

    It is sed to remove the part of stone ,wood or


    metal by placing the sharp edge against the
    material to be removed and pushing or pounding
    the other end with hammer .
    Drawing for Chisel
    Steel Heat/Colour Chart
    Now we move to
    the Demo of the lab

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