This document discusses various metal forging processes. It describes how metal forgings can range in size from small parts to parts weighing 700,000 lbs. It lists examples of common forged parts, such as aircraft, automotive, and tool components. The document then discusses specific forging techniques like heading, piercing, sizing, ball forging, ring forging, riveting, coining, and trimming. It notes factors considered in forging analysis like true strain, required force, flow stress, and forging shape factor.
3. • Metal forgings can be small parts, or weigh as much as
700,000 lbs.
• Products manufactured by forging in modern industry
include critical aircraft parts such as landing gear, shafts for
jet engines and turbines,
• structural components for transportation equipment such as
automobiles and railroads, crankshafts, levers, gears,
connecting rods, hand tools such as chisels, rivets, screws,
and bolts to name a few.
• The manufacture of forging die and the other high costs of
setting up an operation make the production of small
quantities of forged parts expensive on a price per unit basis.
26. Heading Or Upset Forging
• Heading or upset forging is a process by which
stock, (typically cylindrical), is upset at its end in
order to increase the cross section of the material
in this area.
• This metal forging process may be hot, but is
often a cold working operation.
• Cold working will take advantage of the
strengthening of the material in the region
worked.
28. Metal Piercing
• Piercing is a metal forging technique that is often
performed as an auxiliary process in conjunction
with other forging processes, in the manufacture
of a part.
• It can be used to create a cavity or hole in the
work piece
29. Metal Sizing
• Sizing is a metal forging process that is used
mainly to finish work that has already been
manufactured.
• It is a cold forming process.
• Metal sizing uses a lot of force over a short
distance, producing very accurate dimensions in
the finishing of these parts.
• This manufacturing technique can also be used
to create work with excellent surface quality.
30. Metal Ball Forging
• The ability to manufacture metal spheres with very
accurate dimensions and surface quality is
important in modern industry.
• One of the main applications of these metal balls is
for use as ball bearings.
• Ball bearings are widely used in mechanical
systems involving the translation of motion.
31. Ring Forging
• Seamless metal rings of different sizes are
commonly manufactured in modern industry for
various applications, such as parts for machine
tools, rockets, turbines, pipes, and pressure
vessels.
32. Riveting
• Riveting is a forging process that may be used to
join parts together by way of a metal part called
a rivet.
• The rivet acts to join the parts through adjacent
surfaces.
• A straight metal piece is connected through the
parts.
• Then both ends are formed over the
connection, joining the parts securely.
33. Metal Coining
• Metal coining is a forging process by which very
fine and intricate details can be created on the
surface of a work piece.
• Coining may be used to control surface quality
and detail on parts.
• Metal coining is often a finishing process for
manufactured products.
34. Trimming
• Trimming is a manufacturing process that is
used as a finishing operation for forged parts,
in order to remove flash.