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Forging Die Design Calculations Guide

This document provides guidelines for calculating key parameters in forging die design: 1) It gives the formula to calculate forging force based on width of die, width of workpiece, shear flow stress, and thickness before and after forging. 2) It recommends width to thickness ratios of forged parts to be between 3:1 to 5:1. 3) To calculate blank size, it adds percentages for shear, sprue, and scale losses to the net weight of the forging. 4) It provides draft angle ranges for outside and inside faces of dies.

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Raman
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832 views3 pages

Forging Die Design Calculations Guide

This document provides guidelines for calculating key parameters in forging die design: 1) It gives the formula to calculate forging force based on width of die, width of workpiece, shear flow stress, and thickness before and after forging. 2) It recommends width to thickness ratios of forged parts to be between 3:1 to 5:1. 3) To calculate blank size, it adds percentages for shear, sprue, and scale losses to the net weight of the forging. 4) It provides draft angle ranges for outside and inside faces of dies.

Uploaded by

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

FORGING DIE DESIGN CALCULATIONS

1. Forging force: -

p=2bwk[1+b/4t2]

Where b=width of die,


w=width of work,
k=shear flow stress.

2k[1+b/4t2] = Average pressure under the dies


t1 = Thickness of the work before forging
t2 = Thickness of the work after forging

Hint:- w/t1 = not more than 1.5


t1/b = less than 3

2. Width to thickness ratio of forgings :-


= 3:1 to 5:1
3. TO calculate blank size :-

W1 = W+Losses
where,
W1 = weight of stock
W = Net weight of forging
Shear loss = 6% of net weight (W)
Sprue loss = 7% - 8% of net weight
Scale loss = 6% of w
4. Length of stock :-

Length of the stock, (L) = W/f*A

Where,
f = Density of metal
A=Largest cross-section area

5.Draft angles :-
Alpha = Draft angle for outside faces
= 50 - 70
Beta = Draft angle for inside faces
= 70 - 100
6. Minimum section size :-

T = Web thickness = 1/8 x B


Where,
B = Web width
h = height of the rib or web = 4 B – 6 B
7. Mismatch (S) :-
S = 0.3 mm for forging upto 5 kg weight
= 0.5 mm for forgings from 5 – 10 kg weight

8. Tolerances and thickness:-

1 mm on forgings up to 1 kg weight
2 mm on forgings up to 2 – 10 kg weight

Negative tolerances on thickness


0.12 mm up to 1 kg weight
0.5 mm from 2 – 10 kg weight
0.8 mm from 10 – 20 kg weight

Machining allowance
= 1.5 mm per side for up to 5 kg
= 1.5 – 3 mm for medium forgings
= 3 – 6 mm for large forgings
9. Holes and Cavities :-

Maximum depth of cavity (h) = d, and


h = 1.5 d if a full radius allowed at the
bottom.
Where d = Size of diameter.

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