The document discusses various metal forming processes including upsetting, cogging, impression die forging, heading, coining, roll forging, orbital forging, swaging, and their applications. Diagrams illustrate steps and effects of each process.
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Forging PDF
The document discusses various metal forming processes including upsetting, cogging, impression die forging, heading, coining, roll forging, orbital forging, swaging, and their applications. Diagrams illustrate steps and effects of each process.
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Kalpakjian Schmid
Manufacturing Engineering and Technology
2001 Prentice-Hall Page 14-7 Upsetting Figure 14.4 (a) Solid cylindrical billet upset between two flat dies. (b) Uniform deformation of the billet without friction. (c) Deformation with friction. Note barreling of the billet caused by friction forces at the billet-die interfaces. Kalpakjian Schmid Manufacturing Engineering and Technology 2001 Prentice-Hall Page 14-8 Cogging Figure 14.5 Two views of a cogging operation on a rectangular bar. Blacksmiths use this process to reduce the thickness of bars by hammering the part on an anvil. Note the barreling of the workpiece. Kalpakjian Schmid Manufacturing Engineering and Technology 2001 Prentice-Hall Page 14-9 Impression-Die Forging Figure 14.6 Stages in impression-die forging of a solid round billet. Note the formation of flash, which is excess metal that is subsequently trimmed off (see Fig. 14.8). Kalpakjian Schmid Manufacturing Engineering and Technology 2001 Prentice-Hall Page 14-10 Forging a Connecting Rod Figure 14.7 (a) Stages in forging a connecting rod for an internal combustion engine. Note the amount of flash required to ensure proper filling of the die cavities. (b) Fullering, and (c) edging operations to distribute the material when preshaping the blank for forging. Kalpakjian Schmid Manufacturing Engineering and Technology 2001 Prentice-Hall Page 14-13 Coining Figure 14.10 (a) Schematic illustration of the coining process. the earliest coins were made by open-die forging and lacked sharp details. (b) An example of a coining operation to produce an impression of the letter E on a block of metal. Kalpakjian Schmid Manufacturing Engineering and Technology 2001 Prentice-Hall Page 14-15 Heading/Upset Forging Figure 14.11 (a) Heading operation, to form heads on fasteners such as nails and rivets. (b) Sequence of operations to produce a bolt head by heading. Manufacturing Processes for Engineering Materials, 4th ed. Kalpakjian Schmid Prentice Hall, 2003 Heading FIGURE 6.17 Forging heads on fasteners such as bolts and rivets. These processes are called heading. Piercing Operations FIGURE 6.18 Examples of piercing operations. Kalpakjian Schmid Manufacturing Engineering and Technology 2001 Prentice-Hall Page 14-19 Orbital Forging Figure 14.15 (a) Various movements of the upper die in orbital forging (also called rotary, swing, or rocking-die forging); the process is similar to the action of a mortar and pestle. (b) An example of orbital forging. Bevel gears, wheels, and rings for bearings can be made by this process. Kalpakjian Schmid Manufacturing Engineering and Technology 2001 Prentice-Hall Page 14-17 Roll-Forging Figure 14.13 Two examples of the roll-forging operation, also known as cross-rolling. Tapered leaf springs and knives can be made by this process. Source: (a) J. Holub; (b) reprinted with permission of General Motors Corporation. Kalpakjian Schmid Manufacturing Engineering and Technology 2001 Prentice-Hall Page 14-18 Production of Bearing Blanks Figure 14.14 (a) Production of steel balls by the skew-rolling process. (b) Production of steel balls by upsetting a cylindrical blank. Note the formation of flash. The balls made by these processes are subsequently ground and polished for use in ball bearings (see Sections 25.6 and 25.10). Kalpakjian Schmid Manufacturing Engineering and Technology 2001 Prentice-Hall Page 14-20 Swaging Figure 14.16 (a) Schematic illustration of the rotary-swaging process. (b) Forming internal profiles on a tubular workpiece by swaging. (c) A die-closing type swaging machine, showing forming of a stepped shaft. (d) Typical parts made by swaging. Kalpakjian Schmid Manufacturing Engineering and Technology 2001 Prentice-Hall Page 14-21 Swaging of Tubes With and Without a Mandrel Figure 14.17 (a) Swaging of tubes without a mandrel; not the increase in wall thickness in the die gap. (b) Swaging with a mandrel; note that the final wall thickness of the tube depends on the mandrel diameter. (c) Examples of cross-sections of tubes produced by swaging on shaped mandrels. Rifling (spiral grooves) in small gun barrels can be made by this process. Manufacturing Processes for Engineering Materials, 4th ed. Kalpakjian Schmid Prentice Hall, 2003 Presses Used In Metalworking FIGURE 6.28 Schematic illustration of various types of presses used in metalworking. The choice of the press is an important factor in the overall operation. Manufacturing Processes for Engineering Materials, 4th ed. Kalpakjian Schmid Prentice Hall, 2003 Chapter 6 Bulk Deformation Processes Manufacturing Processes for Engineering Materials, 4th ed. Kalpakjian Schmid Prentice Hall, 2003 Grain Flow Lines FIGURE 6.2 Grain flow lines in upsetting a solid steel cylinder at elevated temperatures. Note the highly inhomogenous deformation and barreling. The differnet shape of the botte, section of the specemen (as compared with the top) results from the hot specimenresting on the lower, cool die before deformation proceeded. The bottom surface was chilled; thus it exhibits greater strength and hence deforms less than the top surface. Source: J. A. Schey et al., IIT Research Institute. Kalpakjian Schmid Manufacturing Engineering and Technology 2001 Prentice-Hall Page 14-16 Grain Flow Pattern of Pierced Round Billet Figure 14.12 A pierced round billet, showing grain flow pattern. Source: Courtesy of Ladish Co., Inc. Manufacturing Processes for Engineering Materials, 4th ed. Kalpakjian Schmid Prentice Hall, 2003 Internal Defects In Forging FIGURE 6.24 Internal defects produced in a forging because of an oversized billet. The die cavities are filled prematurely, and the material at the center of the part flows past the filled regions as deformation continues. FIGURE 6.23 Laps formed by buckling of the web during forging. Manufacturing Processes for Engineering Materials, 4th ed. Kalpakjian Schmid Prentice Hall, 2003 Defect Formation In Forging FIGURE 6.25 Effect of fillet radius on defect formation in forging. Small fillets (right side of drawings) cause the defects. Source: Aluminum Company of America.