Forging

PART 2BASIC PROCESSES

Open die forging

die bottom4 forging3billet 2 die top1 forging. die-Open

−−−−

(a) Ideal deformation of a solid cylindrical specimen compressed (a) Ideal deformation of a solid cylindrical specimen compressed between flat frictionless dies. This process is known as between flat frictionless dies. This process is known as upsettingupsetting. . (b) Deformation in upsetting with friction at the die-(b) Deformation in upsetting with friction at the die-workpieceworkpiece interfaces.interfaces.

(a) Ideal deformation of a solid cylindrical (a) Ideal deformation of a solid cylindrical specimen compressed between flat frictionless specimen compressed between flat frictionless dies. This process is known as dies. This process is known as upsettingupsetting..

(b) Deformation in upsetting with friction at the (b) Deformation in upsetting with friction at the die-die-workpieceworkpiece interfaces. interfaces.

Grain flow lines in upsetting a solid steel cylinder at elevated Grain flow lines in upsetting a solid steel cylinder at elevated temperatures. Note the highly temperatures. Note the highly inhomogenousinhomogenous deformation and deformation and barreling. The barreling. The differenetdifferenet shape of the bottom, section of the shape of the bottom, section of the specimen (as compared with the top) results from the hot specimen specimen (as compared with the top) results from the hot specimen resting on the lower, cool die before deformation proceeded. The resting on the lower, cool die before deformation proceeded. The bottom surface was chilled; thus it exhibits greater strength and bottom surface was chilled; thus it exhibits greater strength and hence deforms less than the top surface. hence deforms less than the top surface.

Grain Flow Lines

Changes in the grain structure of cast or large-grain wrought metals Changes in the grain structure of cast or large-grain wrought metals during hot rolling. Hot rolling is an effective way to reduce grain during hot rolling. Hot rolling is an effective way to reduce grain size in metals for improved strength and ductility. Cast structures size in metals for improved strength and ductility. Cast structures of ingots or continuous castings are converted to a wrought of ingots or continuous castings are converted to a wrought structure by hot working.structure by hot working.

Changes In Grain Structure

Upsetting out Drawing

ring pad- 3 workblank,- 2 punch, expanding -1 expending.Punch

process forging Saddle (right) ring; a forging saddlefor Setup (left):expanding Mandrel

Close die forging

landflash 4flash 3 dielower 2 dieupper 1 flash. with forging die-Closed

−−−−

forging 4billet 3 diesplit 2punch 1flash without forging die-Closed

−−−−

Comparison of Forging With and Without Flash

Stages in impression-die forging of a solid round billet. Note the formation of flash, which is excess metal that is subsequently trimmed off

Impression-Die Forging

Die block forging

blank thepreforming when material thedistribute tooperations edging (c) andoperation Fullering (b) ;operationsEach (a)

block; diein rod connecting a of stages Forging

Stages in forging a connecting rod for an internal Stages in forging a connecting rod for an internal combustion engine. Note the amount of flash that is combustion engine. Note the amount of flash that is necessary to fill the die cavities properly.necessary to fill the die cavities properly.

Forging A Connecting Rod

(a) Stages in forging a connecting rod for an internal combustion engine. Note the amount of flash required to ensure proper filling of the die cavities.

Forging a Connecting Rod

(b) Fullering, and (c) edging operations to distribute the material when preshaping the blank for forging.

Forging a Connecting Rod

Trimming flash from a forged part. Note that the thin material at the center is removed by punching.

Trimming Flash from a Forged Part

Extrusion

extrusion forward and backward Combined (c) extrusion. Forward (b) extrusion. Backward (a)

:modelExtrusion

extrusion forward and backward Combined (c) extrusion. Forward (b)

extrusion. Backward (a) :modelExtrusion

extrusion forward and backward Combined (c) extrusion. Forward (b) extrusion. Backward (a)

:modelExtrusion

extrusion forward and backward Combined (c) extrusion. Forward (b) extrusion. Backward (a)

:modelExtrusion

THANK YOU!THANK YOU!THANK YOU!THANK YOU!