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Open Die Forging

The document discusses open die forging and plane strain forging. In open die forging, a workpiece is forged between two flat dies. Plane strain forging involves lateral flow of the work material as the dies come closer together, setting up frictional shear stresses at the die contact surface opposing the metal flow. The stresses along the workpiece vary due to the presence of interface friction between the dies and workpiece.

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Charanjeet Singh
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196 views7 pages

Open Die Forging

The document discusses open die forging and plane strain forging. In open die forging, a workpiece is forged between two flat dies. Plane strain forging involves lateral flow of the work material as the dies come closer together, setting up frictional shear stresses at the die contact surface opposing the metal flow. The stresses along the workpiece vary due to the presence of interface friction between the dies and workpiece.

Uploaded by

Charanjeet Singh
Copyright
© Attribution Non-Commercial (BY-NC)
We take content rights seriously. If you suspect this is your content, claim it here.
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Download as PPTX, PDF, TXT or read online on Scribd
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In open die forging, the work piece is upset, compressed or forged between two flat over hanging dies.

If the co-efficient of friction at the die- work piece interface is zero & if the material is assumed to be rigid perfectly plastic, then the force-required to forge a specimen is equal to the product of yield stress o & the projected area at any instant. Take the case when friction is there in the interface. Plane Strain Forging: Specimen is not free to flow in the direction perpendicular to the plane of the page. As the dies come closer to each other, there is lateral flow of the work material. Due to this, frictional shear stresses are set up at die contact surface,

OPEN DIE FORGING

which are directed towards the centre line, opposing the metal flow.
Due to the presence of interface friction, the horizontal stress x varies along the length of the rectangular work piece. It is assumed that the work piece material behaves like an ideal plastic material, the work piece is in a plastic state & that the stresses do not vary with height. At any instant of forging, the equilibrium equation of a small element of width dx, in the xdirection gives,

(x + d x)Bh - x Bh 2 x dx B = 0 dx /dx - 2 x /h = 0

Plane Strain Open Die Forging

Metal is plastically deformed by passing it between rolls. Rolling is done both hot and cold. The starting material is cast ingot, which is broken down by hot rolling into bloom, billets and slabs, which are further hot rolled into plate, sheet, rod, bar, pipe, rails or structural shapes. Cold rolling is usually a finishing process in which products made by hot rolling are given a good surface finish with increased mechanical strength of the material. The main objective in rolling is to decrease the thickness of the metal. There is negligible increase in width, so that the decrease in thickness results in an increase in length. Fig. Shows the typical geometry for rolling. A metal sheet with a thickness enters the rolls, passes through the roll gap and leaves with a reduced thickness. Since the volume rate of metal flow has to remain constant,

ROLLING

Velocity at exit will be more than velocity at entrance.


The roll has a constant surface velocity. There is relative sliding between the roll and the work piece, Direction of this relative velocity changes at a point along the contact area, This point is known as the no slip point or neutral point, N, where the velocities of roll and work piece will be equal.

Refer notes

DRAWING (WIRE, ROD, TUBE)

Work piece is pulled through a die resulting in reduction in the cross-section.


is the entrance angle and it provides the entry zone to allow the introduction of lubricant into the working zone Also to protect the work material against scoring by die edges. The angle is usually about 40o. is half die angle (usually 6o to 24o) and here the actual reduction is section occur. The die bearing surface or land (a few mm long) serves to guide the wire or rod as it comes out from the working zone of the die. It ensures accuracy of dimensions from the working zone of the die.

It ensues accuracy of dimension and of the sections shape.


The exit zone prevents damage to die bearing and scoring or finished product. There are a number of variables in the drawing process: work-material properties, reduction in cross-sectional area, die angle, drawing speed, and lubrication.

The performance of the operation is affected by a change in one or more of these variables.
The degree of drawing is measured in terms of reduction of area (RA):

For fine wires, the reductions per pass of 15 to 25 % are used.

For coarse wires this value per pass may be 20 to 50 %.


To increase die life, pressure on die should be reduced. This is accomplished by back tension (similar to rolling).

Die life:

This reduces the pressure but increases the drawing tension, d die material can be alloy steels, carbides and diamonds.
Drawing speeds range from about 9 mpm for largest diameter rods and 90 mpm for small rods and coils to 1500 mpm very fine wires. Refer Notes

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