FORGING DIE OF SPANNER

INTRODUCTION
• A wrench or a spanner is a tool to provide grip and mechanical advantage in
applying torque to turn objects.
• The most common shapes are called open ended spanner.
• Die is an impression or an opposite machined copy of an existing shape or
complex structure(generally a ceramic or highly treated metal)used to repeatedly
mimic the desired product shape in a press.
• We are going to make a die for spanner.
• Forging process is used to make the tools so we discuss about forging in this.
• We will be using closed forging so we mainly focus on it .
FORGING
• Plastic deformation:- when forces are applied to a material causing it
to take on new shape. Basis for all forming process.
• Forging is forming method which shapes a metal part through
controlled plastic deformation.
• There is two type of forging on basis of shape.
Open die forging
closed-die forging
OPEN DIE FORGING
• Open-die forging is carried out
between flat dies or dies of very
simple shape.
• • The process is used for mostly
large objects or when the
number of parts produced is
small.
• • Open-die forging is often used
to perform the work-piece for
closed- die forging.
CLOSED FORGING DIE
• The work-piece is deformed
between two die halves which
carry the impressions of the
desired final shape.
• The work-piece is deformed under
high pressure in a closed cavity.
Normally used for smaller
components
• The process provide precision
forging with close dimensional
tolerance.
• Closed dies are expensive.
OPRATION OF FORGING
• Drawing Down: Drawing down is a process of elongate the length and
reduce the cross section area of work piece. Simply in this operation, the
length of work piece increases and the cross section area decreases. In this
process, a compressive force is applied at perpendicular direction of its
length axis. If a tensile force is applied to change its length at parallel to its
length axis, this process is known as wire drawing.
 OPERATIONS OF FORGING
• Upsetting:
Upsetting is just opposite operation to drawing down. In this operation,
the length of work piece decreases and its cross section area increases.
In this process, a compressive force is applied at parallel direction to its
length axis.
TYPES OF FORGING ACCORDING TO TEMPERATURE

a.) Hot Forging:

If the work piece is heated above its recrystallization temperature and then
force is applied, the process is known as hot forging. The recrystallization
temperature of most of metals is half of its melting temperature.

b.) Warm Forging:

Warm forging done at the temperature about 40 percent of its melting point
temperature.

c.) Cold Forging:

Cold forging is done at room temperature. This process gives highest
mechanical properties among all forging processes.
DIE MATERIAL
Die materials Required properties
• Thermal shock resistance
• Thermal fatigue resistance
• High temperature strength
• High wear resistance
• High toughness and ductility
• High hardenability
• High dimensional stability during hardening
• High machinability

Die materials: alloyed steels (with Cr, Mo, W, V), tool steels, cast steels or cast iron. (Heat treatments such are
nitriding or chromium plating are required to improve die life)
NOTE:1) Carbon steels with 0.7-0.85% C are appropriate for small tools and flat impressions.
2) Medium-alloyed tool steels for hammer dies.
3) Highly alloyed steels for high temperature resistant dies used in presses and horizontal forging machines
ADVANTAGES

• Forging gives comparatively tougher product compare to casting.

• The fatigue strength and creep resistance of forge product is higher.
• Forge product has higher mechanical properties.
• Low cost operation.
• This process does not required special skill operator.
• Variety of shapes can be formed by this process.
DISADVANTAGES
• Higher initial cost for big forging presses.
• Secondary finishing process required in hot forging.
• It cannot produce complex shapes.
• Size is limited due to size of press.
• Brittle metal cannot be forged.
APPLICATIONS
• Mainly forged products are used in every mechanical industry.
• Turbine rotor, generator rotor etc. are forged product.
• It gives higher fatigue strength so most of moving parts like
crankshaft, camshaft gears etc. are made by forging operation.
• Cold forging is used to produce chisel, bolts etc.
• These are mostly used in hand tools and hardware manufacturing.
• It is used in ship building in various structure works.
SPANNER MAKING
• Most types of spanner are made using the drop forging process.
• Steel rods are cut into short lengths, called billets, and each one is passed through an
induction heating coil which use electromagnetism to heat the metal to about 1000
degrees Celsius
• The billet is placed in three dies (also known as ‘moulds’) in succession. The upper die
drops onto the billet, forcing it into shape. The first die provides the rough shape of the
spanner, the second the finished shape and the third trims the excess metal from the
formed spanner.
• The ‘trim line’ (the place where the two halves of the die come together) is ground
down to produce a smooth surface and a hydraulic press stamps the manufacturer’s
name and the product details into the spanner’s surface.
• If the spanner has an angled head, a machine bends the end of the spanner into shape.
• If the spanner has a ring or flare nut head, a vertical milling machine cuts a hole
through the centre of the head ready for shaping and sizing with a broach machine.
• Box and spark plug spanners are not made by drop forging. They are made from steel
tubing that is shaped with forming tools which push into the ends of the tube, creating
the profiles.
• The spanners are then tempered to increase the steel’s strength. Tempering
is a specific sequence of heating and cooling which is slightly different for
each type of steel.
• Flare nut heads are created after tempering by cutting a small section out
of the front of the head.
• The spanners are left in a constantly moving tub of ceramic stones and
chemicals for half a day to prepare the surface of the tools for coating.
• Some spanners are electroplated by being dipped in a sequence of baths
containing nickel and chromium solutions. Electricity passing through the
spanner causes particles of metal to stick to the tool, creating a very thin
layer of metal on the surface.
• Others are coated with black oxide by being immersed in a chemical
solution which reacts with the iron in the steel, producing a covering of
magnetite which protects the steel from corrosion
• Spanners are also dipped in a rust inhibitor solution for extra corrosion
protection
• If the spanner has multiple components, they are fitted together,
often by hand. For example, rivets are fitted to hold the heads of flex-
head spanners in place and plastic gears, made using injection
moulding, are fitted into the heads of ratchet spanners.
• Injection-moulded components are made in a mould into which
molten plastic is pushed under pressure. Once the piece is set it can
be removed and ground down to smooth it into the finished
component.
• Fully insulated spanners are made by placing the spanner in an
injection mould and injecting molten plastic into a cavity surrounding
the tool so the spanner emerges with a plastic coating.
• Finally, each tool is tested to ensure it is strong enough to meet the
manufacturer’s standards.