A.

DEFINITION OF WORK WROUGHT

The term "wrought" generally using heat. So Forging (forging) is a metal forming process
plastically by using the style press to change the shape or size of the metal is done. Forging
process can be done in two ways: hot work (hot working) and workmanship (cold working).
Forging (forging) can be done by hand or with a hydraulic machine because it can create
pressure and require greater power. But if using pneumatic power, the power generated is
smaller. Two types of mechanical workmanship which metal plastic deformation and
deformation are hot working and cold working. In the hot work, force the necessary deformation
is lower and mechanical properties do not change much. In cold working, required a larger force,
but the strength of the metal will increase with sufficient means.
Recrystallization temperature of the metal determines the boundary between hot and cold
work .Pengerjaan metal heat carried over or above the recrystallization temperature region work
hardening. Cold work performed under the recrystallization temperature and sometimes takes
place at room temperature. Steel recrystallization temperature range between 500 C and 700 C.
During hot work operations, metals are in a plastic state and is formed by pressure. hot work has
the following advantages:
1. The porosity in the metal can be reduced. Bars [ingot] after casted generally contains many
holes depressed and can be lost by the influence of high-pressure jobs
2. Ketidakmurnianan in the form of inclusion fragmented and dispersed in the metal.
3. coarse grains and refined grains shaped neck. This took place in the area of recrystallization.
4. Physical properties increased, caused by grain refinement. Tenacity in the metal increases.
5. The amount of energy required to change the shape of the steel in hot conditions is much
lower than the energy required for cold working.
The main process of the metal is hot work:
Forging [forging] is divided into 6 ie
1. Forging hammer
2. Forging override
3. forging umset
4. forging press forging press
5. forging rollers
6. Forging cold

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Forging hammer
In the heated metal forging process is overwritten with the steam forging machine between hand
tools or flat die. Forging hand made by the blacksmith is the oldest known way of forging. In the
process can not be obtained ii high accuracy and can not also be done on a complex workpiece.
Heavy wrought objects ranging from a few kilograms to 90 Mg

Figure 3. Diagram illustrating the sequence number of fitting and reduce the cross section of
100 x 100 mm billet into a round rod

forging overwriting
Differences forging hammer and forging die override located on the type used . Closed die
forging using the override , and the workpiece is formed due to impact or pressure , forcing
the hot metal plastic , and fill the form die . The principle works can be seen in Figure 5. In
this operation no metal flow in die burden caused by the barrage . To regulate the flow of
metal during the burden , this operation is divided into several steps . Every step of
changing the form of the work gradually , thus the metal flow can be set up to form the
workpiece .

Gambar 4. Mesin tempa uap dengan rangka terbuka.

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Steel forging temperature for 1100 - 1250 C, copper and its alloys: 750-925 C,
magnesium: 370-450 C closed die forging with having weight ranging from a few grams to 10
Mg.

Gambar 5. Penempaan timpa dengan die tertutup.

There are two kinds of forging machine override namely: steam hammer and hammer
gravity. In pembenturan steam hammer impact pressure caused by force hammer and die when
on the bottom die anyway. 6. In the picture looks hammer piston. To lift the used air or steam
hammer. Can be set high fall with the program, therefore, can produce a more uniform
workpiece. Hammer piston is made with a heavy hammer capacities ranging from 225 kg to
4500 kg. Hammer piston is widely used in industrial hand tools, scissors, spoons, forks, parts,
and aircraft parts.
Forging hammer impact as Figure 7 consists of two cylinders that are dealing in the
horizontal plane, which suppress impeller and die. Material placed on the areas where the two
halves of the die impact met. Deformation in the material to absorb energy. In this process the
material deforms the same on both sides; the contact time between the material and the die
shorter, less energy required compared with other forging processes and objects held
mechanically.
Once completed, all the average forging covered by crust must be cleaned. This can be
done by dipping it in acid, or tumbling bullet growth, depending on the size and composition of
objects during forging wrought If distortions occur, streamlining operations or put the size can
be made
Advantages of forging operation is smooth crystal structure of the metal, closed holes,
machining time that increasing physical properties. Carbon steel, alloy steel wrought iron,
aluminum and copper alloy magnesium alloy can be forged. The disadvantage is that the onset
of inclusion crust and expensive die so it is not economical to form the body in small amounts.

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Gambar 6. Palu piston.

Gambar 7. Mesin tempa impak.

Penempan with closed die has several advantages compared with open die
forging with, among others, the use of more stringent, higher production capacity
and does not need any special skills.
Forging Press
In forging press, metal plastic deformation through suppression occurs very
slowly, which is different from the impact hammer that goes by fast. Vertical press
machine can be driven by mechanical or hydraulic. Pres somewhat faster
mechanics can produce between 4 and 90 MN (Mega Newton). Pressure required
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to form the steel forging temperature varies between 20-190 MPa (Mega Pascal).
The pressure is calculated on the cross-section on the line dividing forging die.
In forging press in most of the energy can be absorbed by the workpiece
being in forging hammer part of the energy transmitted to the machine and
foundation. Reduction and the workpiece is much faster, therefore lower operating
costs. Many parts with irregular shapes and complicated can be forged more
economically with temap override process.
Upset forging
On average berpenampaan rod upset forging clamped in a heated die and the tip is
pressed so as to change the shape as shown in Figure 8. The length of the upset thing 2 or 3
times the diameter of the rod, if not the workpiece to be bent. Progressive perforation is often
done on the upset forging like to make artillery shell casing or cylinder radial engine.

Gambar 8. Penempaan upset.

Sequence of operations to produce a cylindrical object can be seen in Figure 9. Pieces

round material with a certain length heated to forging temperature, then progressively
suppressed material to melobanginya thus obtained form a tube.

Gambar 9. Urutan operasi penempaan silinder menggunakan mesin tempa upset.

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Roll Forging
Short round rod diminished penempangannya or formed tapered with a roller machine.
Shape roller machine shown in Figure 10 where the roller is not completely round, but cut 25-75
% perforation to allow incoming material between rollers. Section groove in accordance with
the round given dihendakinya shape. When the rollers are in the open position, the operator put
the rods are heated in between the rollers. When the roller rotates, the rod is clamped by the
groove rollers and pushed toward the operator. When the roller is open, the rod is pushed back
and rolled again, or moved to the next exit to complete the formation of the next.
For mengerol wheels, tires and metals other similar objects required a slightly different
roller machine. In figure 11 looks process for mengerol wheel. When wheel spin diamer
gradually increases being increasingly thin plate and rim. Wheel rolled until it reaches a
diameter according to the size and then transferred to other pressing machine for the final
formation.

Gambar 10. Prinsip penempaan rol

Gambar 11. Pembutan roda dengan proses penempaan rol panas

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Judging from the type of mold forging is divided into two:

a.

Forging an open mold is forging process that is conducted between two flat mold or
mold that looks very simple. Forging an open mold used in the initial formation of the
workpiece to forging a closed mold.

Open-die forgings; bendakerja pressed between two pieces of the mold (die) flat (almost flat) so
that the metal flow in the lateral direction without being hampered by the surface of the mold.
The forging operation known as upset forging of reducing high bendakerja and add to its
diameter.
Analysis of open-die forgings When the open-die forging is done under ideal conditions is no
friction between the surface bendakerja and mold, resulting in a homogeneous deformation, and
uniform metal radial flow, as shown in Figure 5:11.

Gambar 5.11 Deformasi homogen bendakerja silinder dalam operasi cetakan terbuka
In ideal conditions, the actual strain (true strain) can be determined by:
ln

in which:

h0
h

h0
h

= initial high bendakerja, in (mm)

= height at point berilkutnya, in (mm)

At the end of the suppression, h = high end, hf

The force required to continue the emphasis to high h achieved:
F Yf .A
in which:

F
A
Yf

= gaya, lb (N)
= luas penampang lintang, in 2 (mm2)
= tegangan alir, lb/in2 (MPa).

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A cross-sectional area gradually increases during operation, and vice versa height h will be
reduced. Yf flow stress also increased as a result of hardening bendakerja, except the metal
perfectly plastic (eg in hot work). In these conditions, strain hardening exponent n = 0, and the
flow stress Yf = Y (yield strength of the metal). Force F will reach the maximum price at the end
of emphasis, namely when A and Yf has the highest price.
In the actual operation of the upset forging, deformation is not like in the picture 5:11, because
of the friction between bendakerja the mold surface, as shown in Figure 5:12.

Gambar 5.12 Deformasi sebenarnya bendakerja silinder dalam operasi cetakan terbuka

F Kf .Yf .A

This friction will increase if the work carried out in hot conditions and mold (die) remain in a
cold state. This can lead to:
(1) The increase in the coefficient of friction, and
(2) the transformation of heat from bendakerja to the surface / near surface of the mold, so that
the adjacent bendakerja more difficult to mold a deformable than the middle.
Both of these factors cause upset style that is actually larger than previously predicted. To
calculate the upset force approach can be used formula as follows:
dimana :

Kf

= faktor bentuk penempaan (the forging shape factor)

Kf 1

dimana :

D
h

0,4 D
h

= koefisien gesekan
= diameter benda kerja atau panjang bidang kontak dengan permukaan die,
in (mm)
= tinggi bendakerja, in (mm)

Example question (for open-die forgings):

Bendakerja forged cylindrical shape in a cold state. High initial diameter of 3.0 in and 2.0 in. In
the operation was reduced to 1.5 in height. The work material has a flow curve with K = 50,000
lb / in2 and n = 0.17.
If the coefficient of friction of 0.1 specify style:
a) when the process starts,
b) at a high of 2.5 in and 2 in, and
c) at the high end of the 1.5-in.
Jawab :

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 D2
22
3. .
V h .
9,426
4
4

in3

Pada saat upper die baru menyentuh permukaan bendakerja :

h = 3,0 in dan F = 0
Pada saat mulur (yielding) dimulai, maka h sedikit lebih kecil daripada 3,0 in, dan bila dianggap
regangan = 0,002, maka :
0,17
Yf K n 50.000 0,002
17.384
lb/in2
Pada saat ini D 2,0 in (sedikit lebih besar daripada 2,0 in)

Kf 1

D2
22
.
3,142
4
4

in2

0,4 D
0,4 0,1 2
1
1,027
h
3,0

Jadi gaya tempa pada saat proses dimulai :

F Kf .Yf .A 1,027 17.3843.142 56.077

lb.

Pada saat h = 2,5 in

ln

h0
3
ln
0,1823
h
2,5

Yf K n 50.000 0,1823 0,17 37.438

lb/in2

Bila dianggap volume konstan :

h0 .A0 3 3,142

3,77
h
2,5
in2

A .

D2
4

Kf 1

4.A

4.3,77
2,19

in

0,4 D
0,4 0,1 2,19
1
1,035
h
2,5

F 1,035 37.438 3,77 146.102

lb.

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In the same way, it is obtained:

For h = 2.0 in F = 211 894 lb
For h = 1.5 in F = 317 500 lb
b. Penempaam closed mold is the process of forging the workpiece is formed between
the two pairs of mold that will produce the desired final shape. The workpiece is formed under
high pressure in a closed cavity, and thus can be produced products that have strict dimensions.
In forging a closed mold, first-billet forging billet arranged edges in order to put into place right
next to the forging process.
Impression-die forgings; the workpiece is pressed between a pair of closed mold, so that the
metal flow in the lateral direction gets significant obstacle in forging this operation, a small
amount of metal work flowed into the gap between the two mold forming fins (flash), as can be
seen in Figure 5.10 (b ). Flash is formed between the two molds are to be cut by trimming
process.
Impression-die forging is sometimes also called forging mold closed (closed-die forging), which
form the mold cavity is the opposite form of the object to be created. Stages of impression-die
forging process is shown in Figure 5:15.

Gambar 5.15 Tahapan proses impression-die forging

The raw material of the workpiece in the cylindrical image similar to the different forms of work
in the open-die forging operations. At the time of the end position near the mold flash is formed
by the metal flow in the gap between cetakan.Walaupun flash should be cut at the end of the
operation, but in fact also beneficial to suppress the flow of metal to the gap between the mold,
so that the metal will fill the entire cavity of the mold. In hot forging, metal flow toward the gap
will be hampered because of the thin flash faster to cool down, the pressure on bendakerja will
grow and able to fill in all parts of the mold cavity, in order to obtain a better quality product.
The formula style used in the forging process is the same as that used in the formula style opendie forgings, but with a slightly different interpetasi:

F K f Yf A
dimana :

F
A
Yf
Kf

=
=
=
=

gaya maksimum, lb (N)

luas proyeksi termasuk flash, in2 (mm2)
tegangan alir material, lb/in2 (MPa)
faktor bentuk penempaan

In hot forging price Yf = creep strength (yield) of metal at that temperature. Kf price increase
with increasing complexity of the shape / geometry of the product to be made. Price Kf for
various geometries of products can be seen in Table 5.1.
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Tabel 5.1 Harga Kf untuk berbagai geometri produk

Part shape
Kf
Impression-die forging
Simple shapes with flash
6.0
Chomplex shapes with flash
8.0
Very chomplex shapes with flash
10.0
Flashless forging
Coining (top and bottom surfaces)
6.0
Complex shapes
8.0
Price maximum force reached at the end of forging when most extensive projection and
maximum friction.
Limitations of impression-die forging:
Dimensions of product produced less accurate. If desired, a more accurate dimensions, the final
settlement can be done with the machining process.
Usually the basic geometry of the products that are made do with a forging process, and the parts
that require accuracy that is better done with the machining process, such as holes, threaded, and
surfaces that will be integrated with other components.

Gambar 5.16 Aliran butir kristal (a) penempaan panas dengan penyelesaian akhir pemesinan,
(b) hasil pemesinan

A. KITCHEN WROUGHT
In carrying out the work of forging the necessary equipment and appliances,
such as kitchen forging, cutting tools, punching, stretcher tools, forming tools,
measuring tools, and other tools
B. FUNCTION KITCHEN WROUGHT
The main function of wrought kitchen is a place to burn the workpiece to be
formed. In addition to the work forming, forging may also be implemented in a
variety of jobs such as gilding, soften, connecting with car mats and other
wrought.
C. WROUGHT KITCHEN EQUIPMENT
Kitchen wrought remained generally used in workshops and permanently
placed on top of a foundation kuat.Suatu wrought kitchen requires air blower. Air
blower can be obtained through a variety of ways, either the traditional way, such
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as kitchen forging press is still widely used in rural areas and the use of electric or
hand ventilator.
The main parts of the kitchen remains:
1. Chimney, function to draw the smoke and dust with natural pull system so
that air can be reduced population.
2. Fume hood, to direct the smoke into the chimney.
3. The furnace of fire, where install / burn the workpiece.
4. tubs, to cool the tool and the workpiece.
5. Valve regulator, to enter the intake air into the furnace.
6. The valve exhaust dust, to remove dust and slag residue burning slag.

D. FUEL KITCHEN WROUGHT

There are three kinds of fuel that is used in the kitchen wrought, namely;
solid fuels, liquid fuels, and gaseous fuels.
E. SOLID FUEL
The terms of solid fuels:
1. high carbon levels
2. Solid fuels pretty hard.
3. Grain-grain fuel is not too small.
4. Does not contain fuel TER, because it fouled the ceiling, so that it
becomes black.
Which includes solid fuel is: wood charcoal, charcoal former, coconut shell,
and others in the form of solids and can be burned.
The advantage of solid fuel are:
1. Easy to come by, especially in rural areas.
2. Non-combustible.
Losses Solid fuels are:
1. Space dirty work.
2. Requires extensive storage space.
KITCHEN EQUIPMENT F. WROUGHT
There are lots of forging equipment and their function, among others:
I. Hammer, hammer, there are two kinds of ordinary hammer used to
form / hitting the workpiece and hammer graders are tools to further
flatten the surface of the workpiece.
II. Tongs (clamp) is used to clamp workpieces heat and as a tool in
forging the time.
III. Poker used to take charcoal and coke.
IV. Plakes readjusted coke used in the furnace.
V. Scrapers are used as a fire extinguisher on the edge of the stove.
VI. Anvil is used as a basis when we forge.
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Measurement In Kitchen Forging

Compass for Forging
Measuring devices used in forging namely: forgings compass for use:
setting a compass for forging by using calipers or "block Gauge" according to the
size we want. We can measure the workpiece forging using the compass that has
been set.
Forging Measure Gauge
The tool has been measured in accordance with the existing size (size can be
seen on the device). Forging workpiece can be measured with the device in
accordance with the size we khendaki. There are various profiles of this measure.
BASIC PROCESS G. forge
The definition of basic forging process is a process of which is a basic skill
that must be mastered by forging wrought workers.
Basic processes of forging consists of powering daput wrought, cut,
stretched, flattened, bent, making, hollow and weld wrought.
Many kinds of methods used in the work wrought, among others:
1. Flatten the workpiece (flattening).
2. Make Benja sharp work (sharpening).
3. Make tapered workpiece (pointing).
4. Make the workpiece by means of hitting the upper (Setting Up).
5. Extend or pull a workpiece (drawing) benba .Membengkokan work
(Bending).
H. SERVICE KITCHEN WROUGHT
Operate charcoal wrought kitchen:
How to turn on the kitchen wrought as follows:
1. Clean the furnace of wood shavings from the slag-combustion residual
slag.
2. mound powder - powder wood shavings or materials flammable.
3. Set the position that burned charcoal.
4. Burn earlier filings with matches.
5. Breathe the air little by little until the fuel burning and flaming.
6. Add the charcoal in the center of the furnace when the fire was lit well.
7. Set the greater airflow to the fire burning.
8. Put the workpiece into the fire if the fire had membaradengan well.
How to turn off the kitchen wrought:
1. Turn off the first ventilator
2. Put out the embers and Siramlah with water.
3. Separate the unburned fuel and materials - materials that are still in use.
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Temperature In Kitchen Forging

Temperature and color ideal for workpiece is at a temperature at a
temperature of 800-930 degrees Celsius or in color is yellowish red. Should not be
forged steel below 400 degrees Celsius, it will be brittle steel blue. If the steel is
heated above 1200 degrees Celsius, the steel will be burnt and can not be repaired
anymore. Workpiece used is st.37 with carbon content kuang over 0.3 g.
After studying this topic, you are expected to:
1. Comparing the work wrought by machine work based on the
advantages and kekurangan2 wrought work, and.
2. State 4 kinds of materials that can be wrought by the carbon content
and the steel guide.
3. The advantage is wrought metal work in hot conditions is soft and
easy on the shape of the collision and pressure without damaging the
nature of the metal itself.
4. Other advantages are:
5. The same benda2 in forging stronger than that in working with
mesin.kerja serat2 metal cutting machine, while the work wrought
metal serat2 follow the shape of the object.
6. bentuk2 complex work can be produced more easily and cheaply
riding on the engine work.
7. The establishment will be undertaken by forging, cutting does not
occur, then the amount of metal that is lost or wasted would be less.
8. The labor shortage is wrought:
9. forging temperature that is too high will cause oxidation so that the
workpiece would quickly melt.
10.The exact size / meticulous difficult to achieve.

CLOSING
Conclusion
Forging metals are deformed due to the influence of traction, pressure and
bend that occurs in the heat and cold. Ideal forging process at a temperature of
800-1100 degrees Celsius and yellowish red. Steel should not be forged at
temperatures below 400 degrees Celsius as it would fragile blue brwarna. While
the steel is heated above 1200 degrees Celsius, the steel will be burnt and can not
be repaired anymore. Permanent control of the workpiece every minute until
melted lest workpiece. Each will do the job first forged check equipment available.
And use protective equipment when bekerja.Jagalah salvation yourself.
Suggestion
Not a lot of advice that I wrote but I just remind, among others:
1. When will undergo a job first check the existing fixtures.
2. Use the safety equipment provided.
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3. Pay attention to all that we do is pelejaran we can learn every time.

4. The fixtures in the kitchen can diperlengkap wrought again.
5. Supervision of students who are doing the best practices should be
more aware.
6. Equipment ANVIL considered insufficient to practice becomes
inefficient, should ANIL plus.

DAFTAR PUSTAKA
1. Wijaya, Novi. 2011. Laporan kerja tempa. http//:id.scribd.com/doc/54823293/Laporankerja-tempa. (diakses tgl 3Nov 2012 )
2. Murjito.2007. Laporan Penelitian berorientasi produk Jurusan Teknik Mesin Univ
Muhammadiyah Malang. http//:id.scribd.com/doc/110298475/Laporan-penelitian-PBP
(diakses tgl 3 Nov 2012 )
3. Annonim. 2011. Proses Penempaan http//:nd4s4ch.wordpress.com/2011/03/23/prosespenempaan-forging. (diakses tgl 3 Nov)

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