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Forging Die

The document provides an overview of various forging processes, including upset forging, impression forging, and precision forging, detailing operations such as upsetting, edging, fullering, and coining. It emphasizes the importance of die design, material properties, and the effects of temperature and pressure on the forging process. Additionally, it discusses die failure causes and the significance of proper lubrication and material flow in achieving successful forging outcomes.

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Abhishek kumar
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19 views43 pages

Forging Die

The document provides an overview of various forging processes, including upset forging, impression forging, and precision forging, detailing operations such as upsetting, edging, fullering, and coining. It emphasizes the importance of die design, material properties, and the effects of temperature and pressure on the forging process. Additionally, it discusses die failure causes and the significance of proper lubrication and material flow in achieving successful forging outcomes.

Uploaded by

Abhishek kumar
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
Available Formats
Download as PPTX, PDF, TXT or read online on Scribd
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FORGING

UPSET FORGING
Open Die forging

Impression/Closed Die forging


Flashless / Precision forging
STANDARD TERMINOLOGY
FORGING – OPERATIONS AND
CLASSIFICATIONS

Forging is a metal working process in


which useful shape is obtained in solid
state by hammering or pressing metal.
1. Upsetting
2.
Edging
Endsof thebarareshaped to
requirement using edging dies.
3.
Fullering
Cross sectional area of
the work reduces as metal
flows outward, away from centre
4.
Drawing
Cross sectional area of the work is
reduced with corresponding
increase in length using convex
dies.
5.
Swagin
Cross
g sectional area of
the bar is reduced using
concave dies.
6.
Piercing
Metal flows around the die cavity
as a moving die pierces the metal.
7.
Punching
It is a cutting operationin
whicha required hole is
produced using a punching die.

8. Bending: The metal is bent around


Roll
forging
 In this process, the bar stock is reduced in
cross-section or undergoes change in cross-
section when it is passed through a pair of
grooved rolls made of die steel.
 This process serves as the initial processing
step for forging of parts such as connecting
rod, crank shaft etc.
A particular type of roll forging called
skew rolling is used for making spherical
balls for ball bearings

SKEW ROLLING
Coggi
ng
Successively reducing the
thickness of a bar with open
die forging
• Also called drawing out
•Reducing the thickness of a long section
of a bar without excessive forces or
machining
Forging between two
shaped dies
•Fullering and Edging mater int
distribute specific regions of ial o
the blank
• Blocking creates a rough
shape
Precision
• Forging
True closed
die or
flashless
precise forging
uses
volumes
of material
completely
to
fill die the
cavity
• Undersize blanks will not fill the cavity,
oversize blanks will cause high
pressures and may damage the dies

• • Reduces the number of additional


operations and wasted material

• • Near-net-shape forging (or net-shape)


DIE
INSERTS
COINING

•Coining is for
minting coins and
jewelry
• and
Completely
high pressures
closed
timesdiesstrength (5-6
to th
the obtain
of e
•materia
Lubricants cannotfin
l)
used since e
details be
incompress they are
An example of a coining operation to
produce an impression of the letter E
Die
Design
 Must know workpiece material strength and
ductility, deformation rate, temperature
sensitivity, frictional characteristics

 Forgeability of materials is capability to


undergo deformation without cracking

 Must evaluate shape, size, and complexity


of design

 Material flows in the direction of least


resistance, which is why intermediate
 Preshaping should prevent material
from easily flowing into flash, produce
favorable grain flow patterns, and
minimize friction and wear at the die-
workpiece interface

 Computers can model and predict


material flow
• Parting lines are usually at the largest
cross section
• Flash specifications:
• Flash clearance should be 3% of
maximum forging thickness
• Land that is 2-5 times flash thickness,
then a larger gutter that does not
•Draft angles are needed (7-10 deg
internal, 3-5 external)

• Avoid small radii

• Avoid sharp corners

• Inserts can be used


 Die materials must have strength and
toughness at elevated temperatures,
hardenability, resistance to
mechanical and thermal shock, wear
resistance

 Die selection based on size, required


properties, forging temperature,
operation type, cost, and production
quantities

 Common die materials are tool and die


steels with chromium, nickel,
 Dies are forged from castings, and
then machined and finished as
needed, often with heat treatment to
increase hardness and wear resistance

 Lubricants act as thermal barriers for


hot workpiece and cooler dies,
improve metal flow, and are parting
agents
Die Failure
Causes
 Improper
design
 Defective
Imprope heat treatmentand
material
r finishing
operatio
ns
cycling – usually preheat dies to
 1500-2500
Overhe degrees Celsius
 Excessive
ating wear – chipping or cracking
and impact forces (can be repaired
from
by welding or laser metal deposition)
cracks

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