C-20, B.

S ROAD INDUSTRIAL AREA

GHAZIABAD -210009

SUMMER TRAINING REPORT

ON MECHANICAL
DURATION
25th JULY to 22th AUGUST 2014

SUBMITTED BY
SHUBHAM MALL
DIPLOMA (2nd year)

IIMT COLLEGE OF POLYTECHNIC, GREATER

NOIDA
INCHARGE/VOCATIONAL TRAINING
DILIP SINGH (C.E.O)

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ACKNOWLEDGEMENT
I express my deepest sense of gratitude to my training guides for
their valuable and whole hearted support during my Vocational
Training. I sincerely thank them for their constant guidance and
critical discussion.
I would like to express my sincere thank for their inspiration and
encouragement.
In addition I would like to thank Mr. L N Patidar, Mr.Dhirendra
Yadav, Mr. Chaman Lal, Mr. Shishir Dahiya and Mr. Murari
Kumar for their invaluable guidance.
I am extremely grateful to Mr. DILIP SINGH (C.E.O. Mechanical)
for educating us with adequate knowledge of process, critical
parameters and advise as and when he could.

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Table of Contents
1. Introduction and classification of forging
processes............................................................................................ 3
1.1 Introduction: ....................................................................................................................................... 3
1.2 Forging: ............................................................................................................................................... 3
1.3 Types of forging: ................................................................................................................................. 4
1.4 Open die forging: ................................................................................................................................ 5
1.5 Closed die forging: .............................................................................................................................. 5
1.5.1 Forging load for impression die forging: ........................................................................................... 7
1.6 Precision die forging: ........................................................................................................................... 8
1.7 Flashless forging .................................................................................................................................. 8
1.8 Roll forging: .......................................................................................................................................... 9

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1.9 Rotary forging: ...................................................................................................................................... 9

1. Introduction and classification of forging processes

1.1 Introduction:
Bulk deformation processes involve shaping of materials to finished products
which have small surface area to thickness or surface area to volume ratio.
Sheet metal forming produces parts having large surface area to thickness
ratio. In sheet metal forming thickness variations are not desirable. Examples
for sheet metal forming are: beverage cans, automobile body etc. Bulk forming
processes may be primary processes such as rolling of ingot to blooms or
billets, in which the cast metal is formed into semi-finished raw material. In
secondary forming, the raw materials, such as blooms, billets are converted
into finished parts such as gears, wheels, spanners etc. Rolling, forging,
extrusion and drawing are bulk forming processes. The present module
describes the salient aspects of forging process.
1.2 Forging:
In ancient times, people employed forging for making coins, jewelry, weapons,
Forging is a deformation processing of materials through compressive stress. It
is carried out either hot or cold. Hot forging is done at temperatures above
recrystallization temperatures, typically 0.6 Tm, or above, where Tm is melting
temperature. Warm forging is done in the temperature range: 0.3 Tm to 0.5
Tm. Cold forging has advantages such as good surface finish, high strength and
greater accuracy. Hot forging requires lower loads, because flow stress gets
reduced at higher temperatures. Strain rates in hot working may be high 0.5
to 500 s-1. Strains in hot forging are also high true strains of 2 to 4 are
common. Typical applications of forging include bolts, disks, gears, turbine disk,
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crank shaft, connecting rod, valve bodies, small components for hydraulic
circuits etc. Forging has several advantages. Closer dimensional accuracies
achieved require very little machining after forging. Material saving is the
result. Higher strength, greater productivity, favorable grain orientation, high
degree of surface finish are other merits. However, complex die making is
costly.
1.3 Types of forging:
In forging the material is deformed applying either impact load or gradual load.
Based on the type of loading, forging is classified as hammer forging or press
forging. Hammer forging involves impact load, while press forging involves
gradual loads. Based on the nature of material flow and constraint on flow by
the die/punch, forging is classified as open die forging, impression die forging
and flashless forging.
Open die forging: In this, the work piece is compressed between two platens.
There is no constraint to material flow in lateral direction. Upsetting is an open
die forging in which the billet is subjected to lateral flow by the flat die and
punch. Due to friction the material flow across the thickness is non uniform.
Material adjacent to the die gets restrained from flowing, whereas, the material
at center flows freely. This causes a phenomenon called barreling in upset
forging.

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Fig. 1.3.1: Axisymmetric Upset Forging
strain forging

Fig. 1.3.2: Plane

Impression die forging both die and punch have impressions, shapes which are
imparted onto the work piece. There is more constrained flow in this process.
Moreover, the excess metal flows out of the cavity, forming flash. Flashless
forging in this the work piece is totally constrained to move within die cavity.
No excess material and hence no flash forms. Flashless forging involves high
level of accuracy. Design of shape of die cavity, finished product volume are
important.
1.4 Open die forging:
In open die forging a cylindrical billet is subjected to upsetting between a pair
of flat dies or platens. Under frictionless homogeneous deformation, the height
of the cylinder is reduced and its diameter is increased. Forging of shafts, disks,
rings etc are performed using open die forging technique. Square cast ingots
are converted into round shape by this process. Open die forging is classified
into three main types, namely, cogging, fullering and edging. Fullering and
Edging operations are done to reduce the cross section using convex shaped or
concave shaped dies. Material gets distributed and hence gets elongated and
reduction in thickness happens. Cogging operation involves sequence of
compressions on cast ingots to reduce thickness and lengthen
them into blooms or billets. Flat or contoured dies are used. Swaging is carried
out using a pair of concave dies to obtain bars of smaller diameter.
1.5 Closed die forging:
It is also known as impression die forging. Impressions are made in a pair of
dies. These impressions are transferred to the work piece during deformation. A
small gap between the dies called flash gutter is provided so that the excess
metal can flow into the gutter and form a flash. Flash has got a very important
role during deformation of the work piece inside the die cavity. Due to high
length to thickness ratio of the flash gutter, friction in the gap is very high. Due
to this the material in the flash gap is subjected to high pressure. There is high
resistance to flow. This in turn promotes effective filling of the die cavity. In hot
forging, the flash cools faster as a result of it being smaller in size. This
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enhances the resistance of the flash material to deformation resistance. As a
result of this, the bulk of work piece is forced to deform and fill the die cavity
more effectively even intricate parts of the die cavity is filled.
Flash is subsequently trimmed off in order to obtain the required dimensions on
the forged part. Often multiple steps are required in closed die forging.Flash is
to be properly designed so that the metal could flow and fill the intricate parts
of the die cavity. A thin flash with larger width requires higher forging loads.
Before getting forged to intermediate shape inside the primary die set called
blocking die, the billet is fullered and edged. This is called preforming.
Subsequently, it is forged to final shape and dimensions in the finishing die.
Closer dimensional accuracy is possible in closed die forging. However, higher
forging loads are required. Parts with wider and thinner ribs, or webs are
difficult to forge as they require higher forming loads. Impression dies are
usually provided with taper called draft of 5o in order to facilitate easy removal
of the finished part. Die preheating may be required to prevent the die chilling
effect which may increase the flow stress on the periphery of the billet. As a
result, incomplete filling or cracking of the preform may occur.
Dimensional tolerances in impression die forging may be as close as 0.5% of
the dimensions of the forged part. In case of hot forging, dimensional accuracy
is less. Some of the factors such as die surface finish, draft allowance, accuracy
of die impression dimensions, die wear, lubrication etc control the quality of
finished product.

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Fig.1.5.2: Parameters of impression die forging

Fig.1.5.3: Stages of closed die forging process

1.5.1 Forging load for impression die forging:
Predicting the forging load for impression die forging is rather empirical due to
the complexities of material flow involved. One empirical relation for forging
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load, given by Schey is as followed: F = C1YfAf, where C1is a shape factor or
constraint factor which depends on the complexity of the
forging process. Yfis the flow stress of material at the given strain,Af is the
projected area of the forging. Typical values of C1:
Simple upsetting 1.25 to 2.5 Flashless forging (Coining) 5 to 8 Complex forging
with flash 8 to 12 From the above equation, one can determine the capacity of
forging press, as the force predicted by the empirical equation is the highest.
1.6 Precision die forging:
Near-net-shape forming is possible through precision die forging, in which high
dimensional accuracy, elimination of after-machining and complex shapes of
parts are achieved through precision dies and higher forging loads are
achieved. Alloys of aluminium, titanium, magnesium are commonly precision
forged. Ferrous materials are difficult to precision-forge because of die wear,
higher temperatures of forging, excessive forging loads requirement.
1.7 Flashless forging
It is a closed die forging process in which the work volume is equal to die cavity
volume, with no allowance for flash. Excess material or inadequate material will
lead to defective part. If billet size is less then underfilling takes place. Over
sized billet leads to die damage or damage to the press. A variant of closed die
forging is isothermal forging. In this process, the die is heated up to the
same temperature of the billet. This helps in avoiding die chilling effect on work
piece and lowering of flow stress. This process is suitable for complex parts to
be mass-produced. Coiningis a special type of closed die forging. Complex
impressions are imparted to both surfaces of the blank from the die. Forging
loads involved are very high as high as 6 times the normal loads. Minting of
coins is an example of this process. Coining, when used for improving surface
finish of products is called sizing. Piercing: It is a process in which a punch
makes deep indentations to produce cavity on workpiece. Work piece may be
kept inside a die or may be free. Higher forming loads are required. Heading:
Heads of bolts, nails are made by heading, which is an upsetting process.
Special types of machines are used for heading.

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1.8 Roll forging:
In this process, the bar stock is reduced in cross-section or undergoes change
in cross-section when it is passed through a pair of grooved rolls made of die
steel. This process serves as the initial processing step for forging of parts such
as connecting rod, crank shaft etc. Finished products like tapered shafts, leaf
springs can also be made.

Fig.1.8.1: Roll forging

A particular type of roll forging called skew rolling is used for making
spherical balls for ball bearings. In this process, the cylindrical bar stock is fed
through the gap between a pair of grooved rollers which are rotating.
Continuous rotation of the rolls and the stock gives raise to formation of a
spherical shaped blank, which is subsequently finished to required dimensions.

Fig. 1.8.2: Skew rolling process

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1.9 Rotary forging:
In this process the punch is given orbital rocking motion while pressing the
workpiece. As a result of this the area of contact between work and punch is
reduced. Therefore lower forging loads are sufficient. The final part is formed in
several smaller steps. Example of parts produced by this process includes
bevel gears, wheels, bearing rings.

Fig. 1.9: Swaging

***

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