MetalForming 3 (Forging of Metals)

Assoc Prof Zainal Abidin Ahmad FKM UTM

LectureOutline
1. 2. 3. 4. 5. 6. Introduction Forgingoperations Classificationofforgingprocesses Closedandopendieforgingprocess Effectofforgingonmicrostructure Otherforgingrelatedprocesses
Coining Swaging Rollforging

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1.Introduction

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Introduction
Typicalforgedproductsaresuchasgears, connectingrods,bolts

Landing-gear components for the C5A and C5B transport aircraft, made by forging
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Steps involved in forging a bevel gear with a shaft.

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2.OutlineofForgingandRelated Operations

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ForgingOperations

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ForgingOperations

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ForgingOperations

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3.Classificationsofforgingprocesses
Byequipment
Forginghammerordrophammer Pressforging

Byprocess
Opendieforging Closeddieforging

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Forgingmachines

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Hammerandpressforging processes
Forginghammers
Boardhammer Powerhammer

Forgingpresses
Mechanicalpress Hydraulicpress

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Boardhammer forginghammer

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Forginghammerordrophammer

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Exampleofforging hammerordrop hammer Theenergy suppliedbythe blowisequalto thepotential energyduetothe weightoftheram andtheheightof thefall
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Powerhammer

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Hydraulicpressforging
Usingahydraulicpressor mechanicalpresstoforgethe metal,therefore,givescontinuous formingataslowerrate. Providesdeeperpenetration Betterproperties(more homogeneous) Equipmentisexpensive

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A general view of a 445 MN (50,000 ton) hydraulic press. Source: Wyman-Gordon Company.

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Mechanicalpressmachine

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Mechanical press with an eccentric drive; the eccentric shaft can be replaced by a crankshaft to give the up-and-down motion to the ram
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PrinciplesofVariousForgingMachines(cont.)

Schematic illustration of the principles of various forging machines. (c) Knuckle-joint press. (d) Screw press. (e) Gravity drop hammer.
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Typicalvaluesofvelocityforvariousforging machines

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4.Closedandopendieforging processes

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Opendieforging
Opendieforgingiscarried outbetweenflatdiesor diesofverysimpleshapes Theprocessisusedfor mostlylargeobjectsor whenthenumberofparts producedissmall Opendieforgingisoften usedtopreform the workpieceforcloseddie forging
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Upsetting

Figure 14.4 (a) Solid cylindrical billet upset between two flat dies. (b) Uniform deformation of the billet without friction. (c) Deformation with friction. Note barreling of the billet caused by friction forces at the billet-die interfaces.

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Cogging
Figure 14.5 Two views of a cogging operation on a rectangular bar. Blacksmiths use this process to reduce the thickness of bars by hammering the part on an anvil. Note the barreling of the workpiece.

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ImpressionDie&ClosedDieForging
Fullering g &edging g gareusedtodistributethe material
Fullering materialisdistributedawayfroman area Edging materialisgatheredintoanarea

Blocking Bl ki rough hshaping h i of fthe th part t Impressiondies givethepartitsfinalshape

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Closeddieforging(impressiondieforging)
Theworkpieceisdeformed betweentwodiehalveswhichcarry theimpressions ofthedesiredfinal shape. Theworkpieceisdeformedunder highpressureinaclosedcavity Normallyusedforsmaller components Theprocessprovideprecision forgingwithclosedimensional tolerance Closeddiesareexpensive
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5.Effectofforgingonmicrostructure

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6. Other forging related process Coining

Closed-die forging process Used for minting coins, medallions, & jewelry Lubricants can not be used in coining Can be used to improve surface finish

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Other forging related process Heading/UpsetForging

(a) Heading operation, to form heads on fasteners such as nails and rivets. (b) Sequence of operations to produce a bolt head by heading.
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Other forging related process RollForging

Two examples of the roll-forging operation, also known as crossrolling. Tapered leaf springs and knives can be made by this process..

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Other forging related process ProductionofBearingBlanks

(a) Production of steel balls by the skew-rolling process. (b) Production of steel balls by upsetting a cylindrical blank. Note the formation of flash. The balls made by these processes are subsequently ground and polished for use in ball bearings (see Sections 25.6 and 25.10).
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Other forging related process Swaging

(a) Schematic illustration of the rotary-swaging process. (b) Forming internal profiles on a tubular workpiece by swaging. (c) A dieclosing type swaging machine, showing h i forming f i of f a stepped shaft. (d) Typical parts made by swaging.

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SwagingofTubesWithandWithouta Mandrel

(a) Swaging of tubes without a mandrel; not the increase in wall thickness in the die gap. (b) Swaging with a mandrel; note that the final wall thickness of the tube depends on the mandrel diameter. (c) Examples of cross-sections of tubes produced by swaging on shaped mandrels. Rifling (spiral grooves) in small gun barrels can be made by this process.
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ClassificationofMetalsinDecreasingOrder ofForgeablilty
TABLE 14.3 Metal or alloy Aluminum alloys Magnesium alloys Copper alloys Carbon and lowalloy steels Martensitic stainless steels Austenitic stainless steels Titanium alloys Iron-base superalloys Cobalt-base superalloys Tantalum alloys Molybdenum alloys Nickel-base superalloys Tungsten alloys
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Approximate range of hot forging temperature ( (C) C) 400550 250350 600900 8501150 11001250 11001250 700950 10501180 11801250 10501350 11501350 10501200 12001300
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7.DefectsinForgedParts

Examples of defects in forged parts. (a) Labs formed by web buckling during forging; web thickness should be increased to avoid this problem. (b) Internal defects caused by oversized billet; die cavities are filled prematurely, and the material at the center flows past the filled regions as the dies close.
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RelativeUnitCostsofaSmallConnecting Rod
Relative unit costs of a small connecting rod made by various forging and casting processes. Note that, for large quantities, forging is more economical. Sand casting is the more economical process for fewer than about 20,000 20 000 pieces.

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