Forging & Press

Working
Presented by :
NILESH KABRA
 SUBJECTS OF
• INTREST
INTRODUCTION TO • INTRODUCTION TO PRESS
FORGING WORK
• CLASSIFICATION OF • PRESS
FORGING • CLASSIFICATION OF PRESS
 OPEN DIE FORGING • PRESS WORKING
 CLOSED DIE FORGING OPERATIONS
 DROP FORGING  CUTTING OPERATIONS
 HAMMER FORGING  FORMING OPERATIONS
 PRESS FORGING
 MACHINE FORGING
• FORGING TOOLS
• FORGING
FORGING OPERATIONS
& PRESS WORKING 2
 INTRODUCTION
• Forging is process of
plastically deforming metal
or alloy to a specific shape
by a compressive force
exerted at elevated
temperature by some
external agency like
hammer, press, rolls, dies or
by an upsetting machine.
• Bolts, nuts, nails, cams,
crank shafts, connecting
FORGING & PRESS WORKING 3

rods, axles etc. are

 CLASSIFICATION OF
FORGING
• On the basis of
Forging Process
process :

1. Open die Forging Open die Forging Closed die Forging

2. Closed die Forging Hand Forging

Power Forging

Drop Forging Press Forging

Machine
Forging
Power Hammer Press Forging

• On the basis of
equipment :
1. Drop Forging
2. Power (Hammer & press)
Forging
FORGING & PRESS WORKING 4

3. Hand Forging
 OPEN DIE FORGING
• This process also known as smiths die
forging or flat die forging.
• The operation is carried out between
two flat dies of very simple shape
generally b/w the bottom surface of
hammer & top surface of anvil..
• The workpiece reduces their
height/plastically deform by
compressing it.
• The process is used for mostly large
objects or when the number of parts
produced is small & to perform the
FORGING & PRESS WORKING work-piece for closed-die forging. 5

• Tooling is simple, inexpensive and

 CLOSED DIE
FORGING
• This process is also called
impression die forging.
• In this metal is deformed under
high pressure between two dies
(called tooling) or in a closed
cavity that contain a profile of the
desired part.
• Closed die forging are commonly
use where mass production of
identical & more complex shapes
of greater accuracy are required.
• The process provide precision
forging with close dimensional
tolerance.
• Normally used for smaller
FORGING & PRESS WORKING 6

components.
• Closed dies are expensive.
 DROP FORGING
• It is also called as stamping. It
consists of special type of hammer
known as drop hammer or drop
stamp.
• Perfectly made steel dies are used
for forging.
• The top part of the die is raised by
mechanical links to a certain
height.
• The heated metal placed
accurately in the bottom part of
the die.
• The top part of the die is then
FORGING & PRESS WORKING 7
allowed to fall suddenly.
• This gives a high blow and
 HAMMER
FORGING
• Machine which is work by blow or impact to perform
forging process is known as hammer forging.
• Power hammer • The upper die and
provides greater ram are raised by
capacity, in which the friction rolls
ram is accelerated on gripping the board.
the down stroke by • After releasing the
steam or air pressure board, the ram falls
in addition to gravity. under gravity to
• Steam or air pressure produce the blow
is also used to raise energy.
•
the ram on the • The hammer can
upstroke. Steam drop strike between 860-
FORGING & PRESS WORKING
hammer 150 blows per
minute depending
 PRESS FORGING
• Machine which is work on pressure to perform forging
process is known as press forging.
• The material gets uniformly deform throughout its entire
depth. •
• Hydraulic presses• are load- • The upper die and
restricted machines in which
hydraulic pressure moves a
piston in a cylinder.
• The full press load is
available at any point during
the full stroke of the ram.
•
• Due to slow speed, contact
time is longer at the die-metal
interface, which causes
FORGING & PRESS WORKING 9
problems such a heat lost
from work-piece
• Crank press translates rotary
motion into reciprocating
linear motion of the press
slide.
• The ram stroke is shorter
than in a hammer or
hydraulic press.
• The blow press is more like
squeeze than like the impact
of the hammer, therefore,
dies can be less massive and
die life is longer than with a
hammer.
MECHANICAL PRESS
FORGING & PRESS WORKING 10
 MACHINE FORGING
• In machine forging the
material is only upset to
get the desire shape.
• The die consists of two
parts, one called the
stationary gripper die
which is fixed to the
machine frame and the
other movable gripper die
which moves along with
the die slide of the up
setter. The stock is held
FORGING & PRESS WORKING
then between these two 11
gripper dies.
• It is used for making
 FORGING TOOLS
• The main hand forging tools are as under.
• TONGS :
Tongs are used mainly for
holding work
of many section.
• FLATTER :
Flatter is used to give
smoothness &
accuracy to articles which
have already
been shaped by fullers and
swages.
• SWAGE :
Swage
FORGING isWORKING
& PRESS used to reduce/finish 12

to round,
square/hexagonal form. It
• ANVIL :
Anvil is used for supporting hot job while
hammering is done for shaping it into
various shapes. It is made of cast steel.

• SWAGE BLOCK :
It is used for holding hot bars during
bending, support for punching holes in a
job & various holes.

• FULLERS :
Fullers are used for necking down/to form
depressions.
FORGING & PRESS WORKING 13
 FORGING TOOLS
• HAND HAMMER : • SLEDGE HAMMER : • PUNCH :

• CHISELS
:

FORGING & PRESS WORKING 14

 FORGING
OPERATIONS
• UPSETTING :
It is the operation by which the
thickness/cross-sectional area of the work
piece is increased at the expense of its
length.
• DRAWING DOWN :
It is the operation by which the
thickness/cross-sectional area of the work
piece is reduced by increasing length.
• SETTING DOWN :
It is the
FORGING & PRESSlocal
WORKING thinning operation 15

performed by the set hammer.

• BENDING :
It is the operation by which the bend
may be either curve/sharp corner can be
produced. Bending can be done using
beak of anvil.
• PUNCHING :
It is the process of making holes in the
work piece using punch & hammer.
• WELDING :
It is the process of joining two surfaces
of metal under pressure after they are
heated to the welding temperature.
• CUTTING :
It is a form of chiseling where a long
piece of stock is cut into several pieces
FORGING & PRESS WORKING 16
of required length.
INTRODUCTION TO PRESS
WORKING
•  Press working is a chip-less manufacturing process by
which various components are made from sheet metals. It
involves the working of a sheet between two die. In press
working, the upper die is called a punch. This process is
also termed as cold stamping.
• The machine used for press working is called a Press.
Press is a machine in which there are two or more slides,
which move relatively to compress the material in the
desired shape.
FORGING & PRESS WORKING 17
 PRESS
The main features of a press are:
• A frame which support a ram or a
slide and a
bed, a source of mechanism for
operating the
ram in line with and normal to the
bed.
• The ram is equipped with suitable
punch and a die block is attached
to
the bed.
• A stamping is produced by the
downward
stroke of the
FORGING & PRESS ram when the punch
WORKING 18

moves
 CLASSIFICATION OF PRESS
Different types of presses are classified based on:
• Source of power :
Mechanical, Electrical, Hydraulic, Pneumatic
etcetera
• Number of RAM :
Single, Double, Multiple.
• Method of transmitting power to RAM :
Crank-shaft, Eccentric, Cam type or rack and Pinion
type.
• Design of frame :
Solid frame, C Frame, Movable frame, Tie rod
etcetera.
FORGING & PRESS WORKING 19

• They are also classified based on the purpose and

 PRESS WORKING
OPERATIONS
The sheet metal operations done a press may be grouped into
two categories.
• Cutting operations
• Forming operations
In cutting operations the work piece is stressed by its ultimate
strength. The stresses caused in the metal the applied forces
will be shear stresses. The cutting operations include:
(a) Blanking        (b) Punching         (c) Notching (d)
Perforating       
(e) Trimming       (f) Shaving (g) Slitting              (h)
Lancing
InFORGING
forming operations , the stresses are below the ultimate 20
& PRESS WORKING
strength of the metal .There is no cutting of the metal but only
the contour of the work piece is changed to get the desired
FORGING & PRESS WORKING 21
 CUTTING OPERATIONS
• Blanking:
Blanking is an operation in which the blank obtained is the
desired product, the rest
portion is discarded.
• Punching or Piercing:
Punching is an operation in which the rest portion obtained is
the desired product,
the hole obtained is discarded.
• Notching:
This is cutting operation by which metal pieces are cut from
the edge of the sheet ,
strip or blank.
FORGING & PRESS WORKING 22
• Perforating:
This is a process by which multiple holes are very small and
close together are cut in
a flat sheet metal.
• Trimming:
This operation consists of cutting unwanted excess of material
from the periphery
of a previously formed component.
• Shaving:
The edge of a blanked part are generally rough, uneven and un
square. Accurate
dimensions of the part are obtained by removing a thin strip of
metal along the
edges.
• Slitting:
It refers to the operation of making incomplete holes in a work
piece.
FORGING & PRESS WORKING 23

• Lancing:
 FORMING
•OPERATIONS
Bending:
In this operation; the material in the form of flat sheet or strip
is uniformly
strained around a linear axis which lies in the neutral plane
and perpendicular it’s
the length wise direction of the sheet or metal.
• Drawing:
This is a process of forming a flat work piece into a hollow
shape by means of a
punch which cause the blank into a die cavity.
• Squeezing:
FORGING & PRESS WORKING 24
Under the operation, the metal is caused to flow to all portions
of a die cavity
THANK YOU!!
FOR YOUR KIND ATTENTION