Forging
Forging
Forging
Forging
Edging
Drawing
Piercing
Punching
Fullering
Swaging
Forging operations
Edging is used to shape
the ends of the bars and
to gather metal.
The metal flow is
confined in the
horizontal direction but
it is free to flow
laterally to fill the die.
By process
1) Open - die forging
2)Closed - die forging (Impression Die Forging)
By equipment
1) Forging hammer or drop hammer
2) Forging presses
By temperature of working
1) Cold forging
2)Warm forging
3)Hot forging.
Hammer and press forging processes
Forging hammers There are two basic types of forging hammers used;
• Board hammer
• Power hammer
Forging presses There are two basic types of forging presses available;
• Mechanical presses
• Hydraulic presses
Forming machines
Board hammer –forging hammer
•The upper die and ram are raised by friction rolls
gripping the board.
Board hammer
•This energy will be delivered to the metal work-
piece to produce plastic deformation.
Forging hammer or drop hammer
•Provide rapid impact blows to the surface of the
metal.
Where
m = mass
v = velocity of ram at start of deformation
g = acceleration of gravity
p = air or steam pressure acting on ram cylinder on down
stroke
A = area of ram cylinder
H = height of the ram drop
Hydraulic press forging
•Using a hydraulic press or a mechanical press
to forge the metal, therefore, gives continuous
forming at a slower rate.
• TYPES
– UPSETTING
– COGGING
– SOLID FORGING
– RING FORGING
– COMBINED PROCESSES
OPEN DIE PROCESS
• UPSETTING
OPEN DIE PROCESS
• COGGING
OPEN DIE PROCESS
• COGGING
• Co-efficient of Spread (S) = Width Elongation/ Thickness Contraction
= ln (W1/W0)/ ln(h0/h1)
• RING FORGING
– Slight rotation of the ring on each press stroke
reduces the ring wall uniformly and increases
both the inside and outside diameters. The
height of the ring remains nearly constant, but
may require edging
Open-die forging
µ2 > µ1
µ2
µ1
µ0
•Different parts of dies are liable to permanent deformation and wear resulting from
mechanical and thermal fatigue.
•Important factors: shape of the forging, die materials, how the workpiece is heated, coating of
die surface, the operating temperature (should not exceed the annealingtemperature).
Effect of forging on microstructure
grain structure resulting from (a) forging, (b) machining and (c)casting.
•The formation of a grain structure in forged parts is elongated in the direction of the
deformation.
•The metal flow during forging provides fibrous microstructure (revealed by etching). This
structure gives better mechanical properties in the plane of maximum strain but (perhaps) lower
across the thickness.
•The workpiece often undergo recrystallisation, therefore, provide finer grains compared to the
cast dendritic structure resulting in improved mechanical properties.
Forming textures
Redistribution of metal structures occurring during forming process involves two principle
components;
1) redistribution of inclusions
2) crystallographic orientation of the grains
Redistribution during
forming of
(a) soft inclusions
(b) hard inclusions
2) Crystallographic orientation of the grains
Castings Forgings
• However, appreciable residual stresses and warping can occur on the quenching of steel
forgings in heat treatment.
•Large forgings are subjected to the formation of small cracks, or flakes at the centre of the cross
section. This is associated with the high hydrogen content usually present in steel ingots of large
size, coupled with the presence of residual stresses.
• Large forgings therefore have to be slowly cooled from the working temperature.
Examples: burying the forging in ashes for a period of time or using a controlled cooling furnace.
Typical forging defects
• Surface cracking
• Flash cracking
• Internal cracks
• Die misalignment.
•Flash line crack, after trimming-occurs more often in thin work-pieces. Therefore
should increase the thickness of the flash.
• Cold shut or fold , due to flash or fin from prior forging steps is forced into the
work-piece.
• Internal cracking, due to secondary tensile stress.