Topic 3
Metal Forming & Shaping Processes
(C) Forging
Compiled by:
Norliana Mohd Abbas
Sources:
1. Manufacturing Engineering & Technology 5th Edition, Serope
Kalpakjian, Steven Schmid, Prentice Hall, 2006
2. Fundamentals of Modern Manufacturing: Materials, Processes and
System, Mikell P. Groover, JohnWiley & Sons (Asia), 2007
3. MYM Handout 2009
Overview
Introduction
Definition
Classification of Forging Operations
General Characteristics of Forging Process
Types of Forging Dies
Open-die forging
Impression-die forging
Flashless/Closed-die forging
Forging Defects
Introduction
Deformation process in which work is compressed between two
dies
Oldest of the metal forming operations, dating from about
5000BC
Components: engine crankshafts, connecting rods, gears, aircraft
structural components, jet engine turbine parts
Also, basic metals industries use forging to establish basic form of
large parts that are subsequently machined to final shape and size
Definition
Forging is a basic process in which the workpiece is shaped by
compressive forces applied through various dies and tooling.
Forging may be carried out at room temperature (cold forging) or at
elevated temperatures (warm or hot forging), depending on the
temperature.
Forgings generally are subjected to additional finishing operations, such
as heat treating to modify properties and machining to obtain accurate
final dimensions and surface finish.
These finishing operations can be minimized by precision forging, which is
an important example of net-shape or near-net shape forming processes.
Classification of Forging Operations
Cold vs. hot forging:
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
Impact vs. press forging:
Forge hammer - applies an impact load
Forge press - applies gradual pressure
General Characteristics of Forging Process
Types of Forging Dies
Open-die forging - work is compressed between two flat
dies, allowing metal to flow laterally with minimum
constraint
Impression-die forging - die contains cavity or impression
that is imparted to workpart
Metal flow is constrained so that flash is created
Flashless forging - workpart is completely constrained in die
No excess flash is created
Open-Die Forging
Three types of forging: (a) open-die forging.
Open-Die Forging
The simplest forging operation with compression of workpart
between two flat dies
Similar to compression test when workpart has cylindrical
cross section and is compressed along its axis
Deformation operation reduces height and increases diameter
of work
Common names include upsetting or upset forging
Open-Die Forging with No Friction
If no friction occurs between work and die surfaces, then
homogeneous deformation occurs
Radial flow is uniform throughout workpart height
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) (2) partial compression, and (3) final size.
Open-Die Forging with Friction
Friction between work and die surfaces constrains lateral
flow of work, resulting in barreling effect
In hot open-die forging, effect is even more pronounced due
to heat transfer at and near die surfaces, which cools the
metal and increases its resistance to deformation
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,
(3) final shape.
Impression-Die Forging
Three types of forging: (b) impression-die forging.
Impression-Die Forging
In impression-die forging, the workpiece takes the shape of the die
cavity while being forged between two shaped dies.
This process usually is carried out at elevated temperatures for
enhanced ductility of the metals and to lower the forces.
Impression-Die Forging
Compression of workpart by dies with inverse of desired part
shape
Flash is formed by metal that flows beyond die cavity into
small gap between die plates
Flash must be later trimmed, but it serves an important
function during compression:
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
Impression-Die Forging
Sequence in impression-die forging:
(1) just prior to initial contact with raw workpiece,
(2) partial compression,
(3) final die closure, causing flash to form in gap between die plates.
Impression-Die Forging
Several forming steps often required, with separate die
cavities for each step
Beginning steps redistribute metal for more uniform
deformation and desired metallurgical structure in subsequent
steps
Final steps bring the part to final geometry
Impression-die forging is often performed manually by
skilled operator under adverse conditions
Adv. & Limt. of Impression-die forging
compared to machining from solid stock
Advantages :
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
Closed-die Forging
In true closed-die forging, flash does not form (hence
the term flashless forging), and the workpiece completely
fills the die cavity.
(a) closed-die forging with flash and (b) precision or flashless forging of a round billet.
Flashless Forging
Three types of forging (c) flashless forging.
Flashless Forging
Compression of work in punch and die tooling whose cavity
does not allow for flash
Starting workpart volume must equal die cavity volume
within very close tolerance
Process control more demanding than impression-die forging
Best suited to part geometries that are simple and
symmetrical
Often classified as a precision forging process
Flashless Forging
Flashless forging: (1) just before initial contact with workpiece, (2) partial
compression, and (3) final punch and die closure.
Forging Defects
In addition to surface cracking during forging, other defects also
can develop as a result of the material flow pattern in the die.
Internal defects also may develop from
(a) nonuniform deformation of the material in the die cavity,
(b) temperature gradients throughout the workpiece during
forging,
(c) microstructural changes caused by phase transformations.
Forging Defects
Examples of defects in forged parts.
(a) Laps formed by web buckling during forging; web thickness should be increased to avoid this
problem.
(b) Internal defects caused by an oversized billet. Die cavities are filled prematurely, and the
material at the center flows past the filled regions as the dies close.
END OF PART ‘C’
