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Chapter 1. Forging
1.1 Introduction:
Forging is one of the oldest metal working operations dating back to atleast
4000 B.C. Forging was traditionally done by blacksmiths. The equipments
used were heavy hand hammer and simple anvil.
1.2 Forging:
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1.3 Forgeability:
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Alloys Steels
3. Copper alloys 7. Austenitic stainless 11. Molybdenum
Steels alloys
4. Plain carbon 8. Nickel alloys 12. Tungsten alloys
Steels
1.5 Forging Temperatures:
Forging Temperature oC
Sr.No. Metal / Alloy
Starting Finishing
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I.Strength:
V. Speed of production:
a) Hand forging
b) Power forging:
i. Hammer forging
a) Drop forging
b) Press forging
c) Machine forging
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a) Hand process:
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According to the name this process purely done by hand. The forging
is done on a anvil by hammering the workpiece at suitable
temperature. This temperature attained by heating the workpiece with
tongs.
b) Power forging:
i. Hammer forging:
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a) Drop forging:
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Perfectly made steel dies are used for forging. these dies are
made into two parts as shown in fig.1.4. One part is connected to the
top side and other part is fastened to the anvil block at the bottom
side. The top part of the die is raised by mechanical links to a certain
height. The heated metal placed accurately in the bottom part of the
die. The top part of the die is then allowed to fall suddenly. This gives
a high blow and completes the workpiece in a single operation. This
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process done due to squeezing of the metal into the die cavities.
before dropping
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The devices are used for raising the top part of the die is given
below
i. Belt
ii. Rope
Working process:
At
b) Press forging:
i. Hydraulic presses:
These presses are used for heavy work. Hydraulic presses are
less faster than mechanical presses. But hydraulic presses produce
greater squeezing force than mechanical presses.
These presses are used for light work. Mechanical presses are
faster than hydraulic presses. But mechanical presses not able to
produce greater squeezing force than hydraulic presses.
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c) Machine forging:
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angles. Internal draft angles are about 7° to 10°, and external draft
angles are about 3° to 5°.
Selection of proper radii for corners and fillets is
important to give smooth flow of metal in a die cavity as well as to
improve die life. Small radii and fillets are not allowed due to stress
concentration and fatigue cracking of the dies.
Allowances are provided in forging die design because
machining of forging of forging may be necessary to obtain final
desired dimensional as well as surface finish. To produce a smooth
and accurate cavity with parting plane more care is required.
In a die, better and economical results are will be
obtained if the following points are considered:
I. The die should part along a single flat plane, if at all possible. If
not then parting plane should follow counter of the workpiece.
II. The parting line should be lies in one plane and not close to the
upper or lower edge.
III. Proper draft angles should be provided – at least 3° for
aluminum and 5° to 7° for steel. Also 1° to 5° draft is provided in
press forging and 3° to 10° in drop forging.
IV. Filets radii should be provided.
V. Ribs should be low and wide.
VI. The various sections should be balanced to avoid extreme
differences in metal flow.
VII. Full advantage should be taken of fiber flow lines.
VIII. Dimensional tolerances should not be closer than necessary.
IX. Forged component should be easily able to achive a radial flow
grains or fibers.
X. Too thin section should be avoided for easy flow of metal.
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I. Die materials:
In most of the forging operation large parts are forged
at elevated temperature. Therefore the general requirements for die
materials are:
a) Good strength and toughness at elevated temperatures.
b) Good harden ability and ability to harden uniformaly.
c) Resistance to mechanical and thermal shocks.
d) It should have high wear resistance.
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II. Lubrication:
Lubricants generally reduces friction and wear. They
also act as thermal conductor between hot workpiece and cool dies.
It can slows the cooling rate of workpiece and improving metal flow
or grain flow. It also act as a parting agent.
Wide variety of lubricants can be used in forging:
i. Mineral oils.
ii. Soaps.
In cold forging, Lubricants are generally
applied on the workpiece.
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I. Gear blank:
It can be made by upsetting the bar stock. The pattern of the grain flow
lines in the bar stock is as shown in fig. 1.8 (a). When bar stock is
placed in dies such that the flow lines are vertical. The grain pattern
produced will be radial and gear blank will give greatest strength to the
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Performing processes, such as fullering and edging [fig. 1.9(b) and fig.
1.9(c)] are used to distribute the material into various regions of the
blank. In fullering, material is distributed away from an area. In
edging, it is gathered into a localized area. The part is then formed into
the rough shape of a connecting rod by a process called blocking using
blocker dies. The final operation is the finishing of the forging in close
die forging that give the forging its final shape. The flash is removed
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III. Hook :
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