Forging

 Forging is a process by which metals or alloys are

plastically deformed to the desired shapes by a
compressive force applied with the help of a pair
of dies.
Forging  Because of the manipulative ability of the forging
process, it is possible to closely control the grain
flow in the specific direction, such that the best
mechanical properties can be obtained based on
the specific application.

Grain flow comparison Advantages of Forging

 Discrete shape of product can be produced.
 Mechanical properties and reliability of the materials
increases due to improved grain structure.
 In forging favorable grain orientation of metal is obtained
that strengthen the component
 Forging reduces the grain size of the metal, which increases
strength and toughness.
 Fatigue and creep strength increases.
Dis advantages
 It is an expensive process
 Dimensional accuracy and surface finish is poor.
 Forging operations are limited to simple shapes and has
limitations for parts having undercuts, re‐entrant surfaces, etc.

Forging operations
Drawing is used to reduce the cross-sectional area of the
work piece with concurrent increase in length Edging Fullering
 Closed and open die forging
Types of forgings In open die forging, hammer is direct contact with
work material, the metal is compressed by repeated
Closed die forging Open die forging
blows by a mechanical hammer and shape is
manipulated manually.
surface finish of the work is poor, direct hammer
contact with work may lead to surface cracks.
In closed die forging, work piece is placed between
upper and lower die and forging load applied to the
work through upper and lower die.
The desired configuration is obtained by squeezing the
work piece between two shaped and closed dies.
Better surface finish and avoid surface cracks.

Close and open die forging processes

Flash
• The excess metal added to the stock to ensure
Open die forging complete filling of the die cavity in the finishing
impression is called Flash.
• A flash acts as a cushion for impact blows from the
finishing impression and also helps to restrict the
Closed die forging outward flow of metal, thus helping in filling of thin ribs
and bosses in the upper die.
• The amount of flash depends on the forging size and
may vary from 8 -10% of volume.
Impression-die forging • The flash thickness will depends on the forging load

Gutter
• In addition to the flash, provision should be made in
the die for additional space so that any excess metal
can flow and help in the complete closing of the die.
This is called gutter.
• This will also prevents the formation of a very wide
flash.
 Open die forging machine Sequence of steps in closed die forging

Four basic types of forging machines Forging Methods

Drop forging
 The drop forging die consists of two halves. The lower half of
the die is fixed to the anvil of the machine, while the upper
half is fixed to the ram.
 The heated stock is kept in the lower die while the ram delivers
four to five blows on the metal, in quick succession so that the
metal spreads and completely fills the die cavity.
 When the two die halves close, the complete cavity is formed.

Press Forging
Metal is squeezed gradually by a hydraulic or Advantages of Press Forging over Drop Forging
mechanical press and component is produced in a  Press forging is faster than drop forging
single closing of die, hence the dimensional accuracy  Alignment of the two die halves can be more
is much better than drop forging. easily maintained than with hammering.
 Structural quality of the product is superior to
drop forging as the load is applied gradually.
 There is no surface cracks and surface finish is
high
 With ejectors in the top and bottom dies, it is
possible to handle reduced die drafts.
 Upset forging (Machine forging) Smith Forging
Upsetting is a process of forging a portion of work not • Blacksmith uses this forging method
• Quality of the product depends on the skill of the operator.
the complete work. Increasing the diameter of a • Not used in industry.
material by compressing its length.

Roll forging Swaging

• In this process, the bar stock is reduced in cross-section or In swaging operation, work is surrounded by the dies and
undergoes change in cross-section when it is passed through by repeated hammers, dia. reduces and length increases.
a pair of grooved rolls made of die steel. Riffle barrels are produced by this process
• This process serves as the initial processing step for forging of
parts such as connecting rod, crank shaft etc.

Skew Rolling: A process similar to roll forging is Match List I (Type of Forging) with List II (Operation)
skew rolling, typically used for making ball List I List II
bearings. Round wire or rod is fed into the roll gap, A)Drop Forging 1. Metal is gripped in the dies and
and roughly spherical blanks are formed pressure is applied on the heated end
continuously by the action of the rotating rolls. B)Press Forging 2.Squeezing action
C)Upset Forging 3.Metal is placed between rollers and
pushed
D)Roll Forging 4. Repeated hammer blows
 Forgeability Forging Defects
• Forgeability is generally defines as the capability of
Unfilled Sections: Die cavity is not completely filled, due to
a material to undergo deformation by forging
improper design of die
without cracking.
Cold Shuts or Fold: A cold shut is a discontinuity produced
• Metal which can be formed easily without
when two surfaces of metal fold against each other without
cracking, with low force has good forgeability.
fusing completely.
• Upsetting test and Hot‐twist test are used to
Scale Pits: This defect appears in hot forging when
determine forgeability.
performed in open dies. Some of the oxides will trapped on
• Forgeability increases with temperature.
the surface and after some time these oxides will go away
producing crater over the surface.
Die Shift: this type of defect appears due to mismatch
between two dies.

Flakes: Internal ruptures caused by the improper cooling. Barreling:

Improper Grain Flow: when they are too much temp. Due to temp. difference, when load is applied central portion
gradient, different sizes of grains will form in different of work will deform more when compared to top and bottom
surface is known as Barreling. This can be overcome by
regions, this makes the material un-isotropic.
isothermal forming.
Forging Laps: These are folds of metal squeezed together
during forging. They have irregular contours and occur at
right angles to the direction of metal flow.
Hot tear and thermal cracking: These are surface cracks
occurring due to non‐uniform cooling from the forging
stage or during heat treatment.
Fins & Rags: this type of defect appears when the temp.
of forging is very high. It is the small projections of loose
metal driven into the surface of object.

Sliding
Load Analysis 𝟐𝛍
𝐋−𝐱
Rectangular Bar Forging 𝐏 = 𝟐𝐤𝐞 𝐡

Sticking
Sticking Length 𝟐𝐤
𝒉 𝟏 𝐏 = 𝟐𝐤 + 𝐋−𝐱
𝑿𝒔 = 𝑳 − 𝒍𝒏 𝐡
𝟐𝝁 𝟐𝝁 Both Sticking and Sliding
If Xs< 0(-ve) only sliding
If Xs > L only sticking 𝐊 𝟐𝐊 𝟐𝛍
𝐋−𝐱
𝐏= + 𝐱 − 𝐱 + 𝟐𝐤𝐞 𝐡
If Xs > 0 both sticking & Sliding 𝛍 𝐡 𝐬
𝟎 ≤ 𝑿𝒔 ≤ 𝑳 𝛔𝐱 + 𝐏 = 𝟐𝐊 (K= Flow shear stress)
𝟎 − 𝑿𝒔 𝐒𝐭𝐢𝐜𝐤𝐢𝐧𝐠
𝐗 𝐬 − 𝐋 𝐒𝐥𝐢𝐝𝐢𝐧𝐠 𝐊=
𝛔𝟎
(𝐓𝐫𝐞𝐬𝐜𝐚′𝐬 𝐓𝐡𝐞𝐨𝐫𝐲) 𝐊=
𝛔𝟎
(𝐕𝐨𝐧 − 𝐌𝐢𝐬𝐞𝐬 Theory)
𝟐 𝟑
𝐥𝐨𝐚𝐝
𝐀𝐯𝐠. 𝐝𝐢𝐞 𝐩𝐫𝐞𝐬𝐬𝐮𝐫𝐞 =
𝟐𝐋𝐁
𝐋
𝐅 = ‫𝐱𝐝𝐁𝐏 𝟎׬‬
 Sliding
2𝜇
𝑅−𝑟
Axi-Symmetric Forging 𝑃 = 𝜎0 𝑒 ℎ

h 1 Sticking
R s = R − 2μ ln 2μ
( Tresca’s Theory)
2𝐾
𝑃 = 𝜎0 + 𝑅−𝑟
ℎ
h 1
Rs = R − ln ( Von-Mise’s Theory)
2μ 3μ
Both Sticking & sliding
𝐾 2𝐾 2𝜇
𝑅−𝑟
R s < 0 only sliding P= + 𝑅𝑠 − 𝑟 + 𝜎0 𝑒 ℎ
𝜇 ℎ
R s > R only sticking
R s > 0 both sticking & sliding
𝜎𝑥 + 𝑃 = 2𝐾
0 ≤ R s ≤ R sliding
o - R s sticking 𝑅
R s - R sliding 𝐹 = න 𝑃. 2𝜋𝑟𝑑𝑟
0

GATE 2014 (PI) GATE 2005

In an open die forging, a circular disc is gradually During open die forging process using two flat and parallel dies, a
solid circular steel disc of initial radius (RIN) 200 mm and initial
compressed between two flat platens. The exponential
height (HIN ) 50 mm attains a height (HFN ) of 30 mm and radius of
decay of normal stress on the flat face of the disc, from RFN . Along the die-disc interfaces
the center of the disc towards its periphery, indicates −
𝑅𝐼𝑁
i) The coefficient of friction µ =0.35 1 + 𝑒 𝑅𝐹𝑁
that
ii) In the region Rs<r<RFN sliding Friction prevails
a) there is no sticking friction anywhere on the flat face of 2µ
𝑅𝐹𝑁−𝑟
the disc P= 3𝐾𝑒 𝐻𝐹𝑁
b) sticking friction and sliding friction co‐exist on the flat iii) The value of RS, where sticking condition changes to sliding
friction
face of the disc
c) the flat face of the disc is frictionless
d) there is only sticking friction on the flat face of the disc

GATE PI Q. A strip of metal with initial dimensions

28mmX28mmX160mm is forged between two
A circular disc of 200mm dia and 100mm
flat dies to a final size of 7mmX112mmX160mm.
thick is compressed between two dies to If the coefficient of friction between the job and
a thickness of 50mm. Determine the die is 0.08. which type(s) of friction will act on
Max. die pressure if µ= 0.1, the yield work-die inter face considering middle of the
strength of the material is 230 Mpa. strip as origin
Chapter 16 Forging
Q. No. Answer
1 C
2 C
3 B
4 B
5 B
6 B
7 D
8 B
9 C
10 B
11 C
12 C
13 C
14 C
15 A
16 B
17 C
18 D
19 A
20 A
21 B
22 B
23 C
24 0.693
25 67
26 0.498