FORGING
ROLLING
BULK FORGING
DEFORMATI
ON EXTRUSION
WIRE & BAR
DRAWING
BENDING
DEEP OR CUP
SHEET DRAWING
METAL SHEARING
META WORKING
L
MISCELLAN
FORM EOUS
BULK DEFORMATION PROCESSES
Bulk deformation processes are those
where the thicknesses or cross sections are
reduced or shapes are significantly
changed.
Since the volume of the material remains
constant, changes in one dimension require
proportionate changes in others.
Thus the enveloping surface area changes
significantly, usually increasing as the
product lengthens or the shape becomes more
complex.
BULK DEFORMATION PROCESSES
Starting geometry of the raw material
may be:
cylindrical bars and billets
rectangular billets and slabs
or any of the above similar shapes
(2) FORGING
Forging is a deformation process in
which the work is compressed between two
dies, using either impact or gradual pressure to
form the part.
It is the oldest of the metal forming operations,
dating back to perhaps 5000 BC.
Today, forging is an important industrial process
used to make a variety of high-strength
components for automotive,
aerospace, and other applications.
(2) FORGING
(2) FORGING
These components include engine
crankshafts and connecting rods,
gears, aircraft structural components, and jet
engine turbine parts.
(2) FORGING CLASSIFICATION
One way to classify the operations is by working
temperature.
Hot or warm forging – most common,
due to the significant deformation and the need
to reduce strength and increase ductility of work
metal
Cold forging – advantage: increased
strength that results from strain hardening
(2) FORGING CLASSIFICATION
Either IMPACT OR GRADUAL pressure
is used in forging.
The distinction derives more from the type of
equipment used than differences in process
technology.
A forging machine that applies an impact
load is called a forging hammer, while
one that applies gradual pressure is
called a forging press.
(2) FORGING CLASSIFICATION
Another difference among forging operations is
the degree to which the flow of the work metal
is constrained by the dies.
By this classification, there are three types of
forging operations, shown in Figure :
(a) Open-die Forging,
(b) Impression-die Forging, and
(c) Flashless Forging.
(2) CLASSIFICATION- Open-die Forging
(2) CLASSIFICATION- Impression-die Forging
(2) CLASSIFICATION- Flashless Forging
(2.1) OPEN-DIE FORGING
The simplest case of open-die forging involves
compression of a workpart of cylindrical cross
section between two flat dies.
This forging operation, known as upsetting
or upset forging , reduces the
height of the work and increases its
diameter.
(2.1) OPEN-DIE FORGING with No-Friction
Homogeneous deformation of a cylindrical workpart under ideal
conditions in an open‑die forging operation: (1) start of process with
workpiece at its original length and diameter, (2) partial compression,
and (3) final size.
(2.1) OPEN-DIE FORGING with Friction
Friction between work and die surfaces constrains
lateral flow of work, resulting in barreling
effect.
When performed on a hot workpart with cold dies,
the barreling effect is even more pronounced.
This results from a higher coefficient of
friction typical in hot working and heat transfer at
and near the die surfaces, which cools the metal and
increases its resistance to deformation.
The hotter metal in the middle of the part flows more
readily than the cooler metal at the ends.
(2.1) OPEN-DIE FORGING with Friction
Actual deformation of a cylindrical workpart in open‑die forging,
showing pronounced barreling: (1) start of process, (2) partial
deformation, and (3) final shape.
(2.2) IMPRESSION-DIE FORGING
Impression-die forging, sometimes called
closed-die forging , is performed with
dies that contain the inverse of the desired
shape of the part.
The process is illustrated in a three-step
sequence in Figure.
The raw workpiece is shown as a cylindrical part
similar to that used in the previous open-die
operation .
(2.2) IMPRESSION-DIE FORGING
Sequence in impression‑die forging: (1) just prior to initial
contact with raw workpiece, (2) partial compression, and (3) final
die closure, causing flash to form in gap between die plates.
(2.2) IMPRESSION-DIE FORGING
As the die closes to its final position , flash is
formed by metal that flows beyond the die
cavity and in to the small gap between the die
plates.
Although this flash must be cut away from
the part in a subsequent trimming operation, it
actually serves two important functions during
impression-die forging.
As flash forms, friction resists continued
metal flow into gap, constraining material
to fill die cavity
In hot forging, metal flow is further
restricted by cooling against die plates
(2.2) IMPRESSION-DIE FORGING
Trimming operation (shearing process) to remove the flash after
impression‑die forging.
(2.2) IMPRESSION-DIE FORGING
Advantages of impression-die forging
compared to machining :
Higher production rates
Less waste of metal
Greater strength
Favorable grain orientation in the metal
Limitations:
Not capable of close tolerances
Machining often required to achieve accuracies and
features needed
(2.2) IMPRESSION-DIE FORGING (connecting rod)
(2.2) IMPRESSION-DIE FORGING (connecting rod)
Flash
Flash
(2.2) IMPRESSION-DIE FORGING (connecting rod)
(2.2) IMPRESSION-DIE FORGING (open wrench)
(2.2)
IMPRESSION-DIE
FORGING (crank
shaft)
(2.3) FLASHLESS FORGING (PRECISION
FORGING)
Impression-die forging is sometimes
called closed-die forging in industry
terminology.
However, there is a technical distinction
between impression-die forging and true closed-
die forging.
The distinction is that in closed-die
forging, the raw workpiece is completely
contained with in the die cavity during
compression , and no flash is formed .
The process sequence is illustrated in Figure.
(2.3) FLASHLESS FORGING (PRECISION
FORGING)
Flashless forging: (1) just before initial contact with workpiece, (2)
partial compression, and (3) final punch and die closure.
(2.3) FLASHLESS FORGING (PRECISION
FORGING)
Flashless forging imposes requirements on
process control that are more demanding than
impression- die forging.
Most important is that the work volume
must equal the space in the die cavity
with in a very close tolerance.
If the starting blank is too large, excessive
pressures may cause damage to the
die or press.
If the blank is too small , the cavity will
not be filled.
(2.3) FLASHLESS FORGING (PRECISION
FORGING)
Because of the special demands made by flash
less forging, the process lends itself best to
part geometries that are usually simple
and symmetrical, and to work materials
such as aluminium and magnesium and their
alloys.
Flashless forging is often referred as a
precision forging process.
Examples: Open Die Forging
Schematic
illustration of a
cogging operation
on a rectangular
bar. Blacksmiths use
a similar procedure
to reduce the
thickness of parts
in small increments
by heating the
workpiece and
hammering it
numerous times
along the length of
the part.
Examples: Open Die Forging
Reducing the
diameter of a
bar by open-die
forging
Or
Open Die Forging
of a multi
diameter shaft
Examples: Open Die Forging
The thickness of
a ring being
reduced by open-
die forging
Examples: Open Die Forging
Making of a crane hook by open die forging
Seamless Rolled Ring Forging Process
Operations
The production of seamless forged rings is often
performed by a process called ring rolling on
rolling mills.
The process starts with a circular preform of
metal that has been previously upset and
pierced (using the open die forging process) to
form a hollow "donut".
This donut is heated above the recrystallization
temperature and placed over the idler or
mandrel roll.
Seamless Rolled Ring Forging Process
Operations
This idler roll then moves under pressure toward
a drive roll that continuously rotates to reduce
the wall thickness, thereby increasing the
diameters of the resulting ring.
Starting stock cut to size by weight is first rounded, then upset to
reduce the height.
Workpiece is punched, then pierced to achieve starting
“donut” shape needed for ring rolling process.
Completed preform ready for placement on ring mill for rolling.
Ring rolling process begins with the idler roll applying
pressure to the preform against the drive roll.
Ring diameters are increased as the continuous pressure
reduces the wall thickness. The axial rolls control the height of
the ring as it is being rolled.
The process continues until the desired size is attained.
Forging Hammers (Drop Hammers)
Apply impact load against workpart
Two types:
Gravity drop hammers - impact energy from
falling weight of a heavy ram
Power drop hammers - accelerate the ram
by pressurized air or steam
Disadvantage: impact energy transmitted
through anvil into floor of building
Commonly used for impression-die
forging
Diagram showing details of a drop hammer for
impression‑die forging.
