Forging INPRODUCTION tink An eater 100 ihe polling op 0 MV A hy ” type af manitite tune linge Preenty wherein me en and Hine ceed #6 Havant a haninier, prenth OF rolls, the compres We ; Ii, HE iv cuttlecd Hand Ponyiny wd WG CUNARD yoy dnt, Most frying, operations ae CH Ot Nel, is forgings In perform a/ithy rnectal al OF CAE Fea one 2 val parts made by forging, in nodern induc Jot engines and turbines, autennhile a ctlny, rods, hand tools like chives, tives, ws Honea 0 roveyatalligation of compressive fren t anally by using specifi (00 using machines, (Hix called Power contain metals may be eald forged, Les (below reoryatallization temperature). ‘Typle airoratt components like landing penn, whalls for xshatls, levers, nears, CONN variety of component for other applications, in use for producing quality forges cng ing, was performed by a blacksmith’ w« Moy components like eran andl bolts, and a wide Tixlay, although various machines and equipments ar itis worth mentioning here that traditionally, for tools such as hammer, anvil, tongs, and chisel, and even today many products like ya and day-to-day usable tools like axe, digging rods, te. are forge cusses the various forging processes, essential in understanding the mec agricultural implements, ct finished bya blacksmith, ‘The pre i parameters, and characteristics tha desi forging proces 3.2) CLASSIFICATION OF FORGING PROCES Forging proc be ied by the degree to which the flow of the work material is ¢ during the process. The three broad categories of forging process are: * Recrystallization is a process by which deformed grai thar nucleate ana growuntl the re pret replaced by a new set of undeform at which complete reerystallization takes place is called entirely consumed, The minimum is usually accompanied by a reduction inthe strength and] wa pees, Fee increase in the ductility swrength and hardness of a material and a 5 + A blacksmith is a person who creates obj ite hammer ansl chisel ote, The wont bac et the metal (usually i ing anvil elise, ete. The word black in blacksmith rofers drake gee gon hE formed onthe surface ofthe metal after being heated, and the on fo ola fre scale, 21332? ns imeaning hit, Thus a blacksmith is a person who hae bck se derives from an ol 7 ‘S Olack metal, Scanned with CamScannera) Opendie forging by Impression die toring, and ©) Closed die tionging (Hlashless tonging) AML Open Die Forging Openadie forging, also called as Smith & forging or flat die forging is carried out between flat dies that do not enclose the workpiece as shown in figure 3.1. The dies are usually ape, but some have simple contoured shapes like round, coneave, or conver surtice for specialized operations. The heated workpiece metal is placed ona bottom die, which may be a anvil or pres bed, while the top die attached to a tee procating ram strikes repeatedly to deform the workpiece, The operator noads to orient and position the workpiece betore each stroke of the ram, in onder to get the desired shapeand size, Secondary operations like machining may be carried out suitably ifneed be. Force Top dio | sipulator (moving to orient { & position workpiece Hot workpioce == — | Bottom Work + dio or boing manipulated anwil (fixed) (a) Starting stock held by manipulator {b) Open die forging Support Support (c) Lathe turning to nearnot shape Figure 3.1 Open die forging of stepped shalt Advantages of open die forging a) Process is relatively simple. b) Makes use of simple, inexpensive di ©) Forged components exhibit good strength characteristics. Scanned with CamScannerManufacty ing P, "ro, 44 be accommodated in clos Ni sized components that cannot be accomn ated in closed digg ’ d) Suitable for larg ee " quired is too small to justify the — Fey, ©) Preferred when the number of components re dies. Disadvantages of open die forging a) Process is limited to simple shapes. +) Skilled operators required for proper manipulation of the workpiece during forgn, ¢) Difficult to maintain close tolerances. d) Low production rate. ¢) Machining to final shape is necessary. Impression Die Forging Impression die forging makes use of matched dies with contoured impression in each dig. y the avo die halves close, the impressions form a cavity whose shape is similar to that ofthe product. The two die halves do not fully close with each other, instead designed with asmay between them. Refer figure 3.2(b). This gap is referred as flash gutter, and its function ne? explsined under the heading Note atthe end of tis discussion. oe Force Top die _ (moving) cae RE oi ea Cel ; Flash (a) {b) Figure 3.2 _ Impression die forging Inimpression die forgi . : anvil or press bed, earl ees metal is placed in the bottom die, which is attached 0 down causing the top die to force nen 2 feeiPrOcating ram of the machine. Thera may impact the workpiece several tig heated metal to fill the contours of the die blocks. Tie" Come together for the finishing ste, Imes to ensure all of the contours are filled, When thetv0o* atin ribbon of metal called lash, Whence metal presentis squeezed out ofthe deo "sing is completed, the flash is trimmed offs” Note In commercial applications. fallering, edging, blocking, eta net PtSsion die forging involves pre-forming procs" ~ $0.48 to give a rough shape to the desired product. TH id Scanned with CamScannersion dics Lo give the forging, its final shay ely filled, Since metal, there will operation being the finishing of the forging i js important to use enough metal in the forging billet so that the die cavity is com pre-forging operations like fullering, edging, ete, are carried out on the workpie of metal during these operations, Hence it becomes difficull to calculate the fing metal required to produce the final part, ILis customary to use a slight come together for the finishing step, the excess metal equi the cavity as a thin ribbon of metal called flash, For this reason, the die is provided with a small opening called flash gutter to accomodate the excess metal, ‘The fash cools more rapidly than the rest of the material; this cool metal being stronger than the metal in the die helps prevent more flash from forming. This also forces the metal to completely fill the die cavity. When the forging is completed, the flash is trimmed off'suitably. be some lo volume of metal, so that when the dies Advantages of Impression die forging a) Suitable forsmall and medium sized components and in large quantit b) Produces dimensionally accurate forgings. ©) Good surface finish can be obtained. @) Excess metals forced out of the die cavity as flash, thereby eliminating pressure build-up in the die cavity. This also improves the life of the dies, Disadvantages of Impression die forging a) Not suitable for large sized components. b) Initial die costs make the process suitable for mass production only, 3.2.3 Closed Die Forging Closed die forging is a precision forging in which the entire volume of the work material is enclosed within the die and no material is allowed to escape from the mould during the forging process. As a result, no flash is formed and for this reason, the process is also called flashless forging. Force a) tb) Top die (moving) Figure 3.3 Closed die forging ——__ a Scanned with CamScanner* Manuf tcturing py, Oey, 46 ; ey Inclosed die forging, the workpiece is deformed between Lk tie halves whichen the mg of the desired shape of the product. Refer figure 3.3. The o is ; ned oan tam of the machine, while the bottom die is attached to the anvil or press ed of the ™aching heated workpiece is placed in the bottom die, the ram falls down causing the top die, fog heated metal to fill the contours of the die blocks. The ram may impact the Workpeicg i times to ensure all of the contours are filled. / ty Note The desired final shape cannot be obtained by forging the workpiece into the die instead some pre-forging steps are always necessary and these steps can be Accomplished i open die forgingand impression die forging processes. These processes bring the workpig, closer tothe final configuration, which is then completed withthe hep of closed die forging. Dt Advantages of closed die forging a) Suitable for small and medium sized components and in large quantities. b) Close dimensional tolerances can be achieved. ©) Good surface finish can be obtained. Disadvantages of closed die forging a) Not suitable for large sized components. ») Initial die costs make it suitable for mass production only. ©) Demands rigorous process control, particularly in the amount of starting material to be u's the workpiece, For example, too little material results in incomplete filling of die cavity zn oo much material will cause a dangerous build up of forces causing the dies to jam orl prematurely. 3.3. FORGING MACHINES & EQUIPMENT There are different types of machines used to perform a forging operation. ‘These machinesse classified under two major categories as listed below: Forging machines -—_ Hammer (Power Hammer) Presses (Power Press) © Gravity drop hammer © Power drop hammer (Air or steam hammer) * Pneumatic hammer * Spring hammer © Counter blow hammer * Mechanical press * Hydraulic press * Screw press 4 Scanned with CamScanner