Scribd
Upload
20 views21 pages

Metal Forming Lect 5

The document discusses various metal forming processes including forging, heading, swaging, roll forging and trimming. It describes the processes, equipment used, defects that may occur and factors affecting forgeability of metals.

Uploaded by

e22mecu0009
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
Available Formats
Download as PDF, TXT or read online on Scribd
20 views21 pages

Metal Forming Lect 5

The document discusses various metal forming processes including forging, heading, swaging, roll forging and trimming. It describes the processes, equipment used, defects that may occur and factors affecting forgeability of metals.

Uploaded by

e22mecu0009
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
Available Formats
Download as PDF, TXT or read online on Scribd
You are on page 1/ 21

LECTURE 5: METAL FORMING PROCESSES

FORGING Processes
Flashless Forging

(1) Just before contact with workpiece, (2) partial compression, and
(3) final punch and die closure
Forging Hammers

1) Apply impact load against work part: There are two types of
forging hammers:
a) Gravity drop hammers - impact energy from falling
weight of a heavy ram
b) Power drop hammers - accelerate the ram by pressurized
air or steam
2) Disadvantage: impact energy transmitted through anvil into
floor of building
3) Commonly used for impression-die forging
Gravity Drop Hammer

Diagram showing details of a drop


hammer for impression-die forging
Forging Presses

1) Apply gradual pressure to accomplish compression operation


2) Different types of presses are :
a) Mechanical press - converts rotation of drive motor into
linear motion of ram
b) Hydraulic press - hydraulic piston actuates ram
c) Screw press - screw mechanism drives ram
Preforming Operations

Preforming operations typically are used


to distribute the material properly into
various regions of the blank using simple
shaped dies of various contours.
Upsetting and Heading

1) Forging process used to form heads on nails, bolts, and


similar hardware products
2) More parts produced by upsetting than any other forging
operation
3) Performed cold, warm, or hot on machines called headers
or formers
4) Wire or bar stock is fed into machine, end is headed, then
piece is cut to length
5) For bolts and screws, thread rolling is then used to form
threads
Upset Forging

Upset forging to form a head on a bolt: (1) wire stock is fed to stop, (2)
gripping dies close on stock, stop retracts, (3) punch moves forward, (4)
bottoms to form the head
Heading (Upset Forging)

(a) Heading a nail using open dies, (b) round head formed by
punch, (c) and (d) two head styles for screws formed by die,
(e) carriage bolt head formed by punch and die
Swaging

1) It is accomplished by rotating dies that hammer a


workpiece radially inward to taper it as the piece is
fed into the dies
2) Used to reduce diameter of tube or solid rod stock
3) Mandrel sometimes required to control shape and
size of internal diameter of tubular parts
Swaging and Radial Forging

1) Swaging process to reduce solid rod stock; dies rotate as they


hammer the work
2) In radial forging, work piece rotates while dies remain in a fixed
orientation as they hammer the work
Roll Forging

1. Roll forging or roll forming is a forging technique that utilizes


opposing rolls to shape a metal part. Even though roll forging
uses rolls in order to accomplish the deformation of the material,
it is classified as a metal forging process and not a rolling
process.
2. It is a discrete process and not a continuous one. The precisely
shaped geometry of grooves on the roll, forge the part to the
required dimensions. The forging geometry of the rolls used to
forge metal parts is only present over a portion of the roll's
circumference. Only part of a full revolution of a roll is needed
to forge the work piece.
3. Roll forging is usually performed hot.
Trimming

1) Cutting operation to remove flash from work part in impression-die


forging
2) Usually done while work is still hot, so a separate trimming press
is included at the forging station
ISOTHERMAL FORGING

• In this material and the forging dies are maintained at


the same temperature. Hence, it is performed as hot
forging operation.
• By avoiding the chill of the part contacting the cold die
surface, the metal flows more rapidly and the forging
force is reduced.
• This process is more expensive than conventional
forging and generally, it is limited to low forgeability
metals like Titanium, superalloys etc.
• Sometimes it is carried out in Vacuum to prevent
oxidation of dies at high temperature.
Forgeability of Metals

Forgeability is generally defined as the capability of a material


to undergo deformation without cracking.
Forging Defects

In addition to surface cracking, other defects can develop during


forging as a result of the material flow pattern in the die.

Web thickness must be increased to avoid this problem


Internal defects caused by oversized billet. Die cavities are filled
prematurely, and the material at the center flows past the filled
regions as the dies close.
A solid cylindrical slug made of 304 stainless steel is 150 mm in
diameter and 100 mm high. It is reduced in height by 50% at room
temperature by open-die forging with flat dies. Assuming that the
coefficient of friction is 0.2 and the flow stress of this material is
1000 MPa, calculate the forging force at the end of the stroke.
0.4 𝜇𝐷
𝐤𝑓 = 1 +
ℎ

You might also like