Forging & Press Working

Forging & Press Working

Presented by : NILESH KABRA

FORGING & PRESS WORKING 2

SUBJECTS OF INTREST• INTRODUCTION TO

FORGING• CLASSIFICATION OF FORGING

OPEN DIE FORGING CLOSED DIE FORGING DROP FORGING HAMMER FORGING PRESS FORGING MACHINE FORGING

• FORGING TOOLS• FORGING OPERATIONS

• INTRODUCTION TO PRESS WORK• PRESS• CLASSIFICATION OF PRESS• PRESS WORKING OPERATIONS

CUTTING OPERATIONS FORMING OPERATIONS


INTRODUCTION• Forging is process of

plastically deforming metal or alloy to a specific shape by a compressive force exerted at elevated temperature by some external agency like hammer, press, rolls, dies or by an upsetting machine.

• Bolts, nuts, nails, cams, crank shafts, connecting rods, axles etc. are produced by forging.


CLASSIFICATION OF FORGING• On the basis of

process :

1. Open die Forging2. Closed die Forging

• On the basis of equipment :

1. Drop Forging 2. Power (Hammer & press)

Forging3. Hand Forging4. Machine Forging

Forging Process

Open die Forging

Hand Forging

Power Forging

Power Hammer

Press Forging

Closed die Forging

Drop Forging

Press Forging

Machine Forging


OPEN DIE FORGING• This process also known as smiths die

forging or flat die forging.• The operation is carried out between

two flat dies of very simple shape generally b/w the bottom surface of hammer & top surface of anvil..

• The workpiece reduces their height/plastically deform by compressing it.

• The process is used for mostly large objects or when the number of parts produced is small & to perform the work-piece for closed-die forging.

• Tooling is simple, inexpensive and allows the production of a large variety of shapes.


CLOSED DIE FORGING• This process is also called

impression die forging.• In this metal is deformed under

high pressure between two dies (called tooling) or in a closed cavity that contain a profile of the desired part.

• Closed die forging are commonly use where mass production of identical & more complex shapes of greater accuracy are required.

• The process provide precision forging with close dimensional tolerance.

• Normally used for smaller components.

• Closed dies are expensive.


DROP FORGING• It is also called as stamping. It

consists of special type of hammer known as drop hammer or drop stamp.

• Perfectly made steel dies are used for forging.

• 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.


HAMMER FORGING• Machine which is work by blow or impact to perform

forging process is known as hammer forging.

Steam drop hammer

•

• Power hammer provides greater capacity, in which the ram is accelerated on the down stroke by steam or air pressure in addition to gravity.

• Steam or air pressure is also used to raise the ram on the upstroke.

• The upper die and ram are raised by friction rolls gripping the board.

• After releasing the board, the ram falls under gravity to produce the blow energy.

• The hammer can strike between 60-150 blows per minute depending on size and capacity.


PRESS FORGING• Machine which is work on pressure to perform forging

process is known as press forging.• The material gets uniformly deform throughout its entire

depth.

•

• Hydraulic presses are load-restricted machines in which hydraulic pressure moves a piston in a cylinder.

• The full press load is available at any point during the full stroke of the ram.

• Due to slow speed, contact time is longer at the die-metal interface, which causes problems such a heat lost from work-piece

• The upper die and

••


• Crank press translates rotary motion into reciprocating linear motion of the press slide.

• The ram stroke is shorter than in a hammer or hydraulic press.

• The blow press is more like squeeze than like the impact of the hammer, therefore, dies can be less massive and die life is longer than with a hammer.

MECHANICAL PRESS


MACHINE FORGING• In machine forging the

material is only upset to get the desire shape.

• The die consists of two parts, one called the stationary gripper die which is fixed to the machine frame and the other movable gripper die which moves along with the die slide of the up setter. The stock is held then between these two gripper dies.

• It is used for making gears, blanks, shafts, excels, and similar parts.


FORGING TOOLS• The main hand forging tools are as under.

• TONGS : Tongs are used mainly for holding work of many section.• FLATTER : Flatter is used to give smoothness & accuracy to articles which have already been shaped by fullers and swages.• SWAGE : Swage is used to reduce/finish to round, square/hexagonal form. It consists of two parts-The top part having a handle. The bottom part having a square shank.

FORGING & PRESS WORKING 13FORGING & PRESS WORKING 13

• ANVIL : Anvil is used for supporting hot job while

hammering is done for shaping it into various shapes. It is made of cast steel.

• SWAGE BLOCK : It is used for holding hot bars during

bending, support for punching holes in a job & various holes.

• FULLERS : Fullers are used for necking down/to form

depressions.


FORGING TOOLS

• HAND HAMMER :

• SLEDGE HAMMER :

• PUNCH :

• CHISELS :


FORGING OPERATIONS• UPSETTING :

It is the operation by which the thickness/cross-sectional area of the work piece is increased at the expense of its length.

• DRAWING DOWN : It is the operation by which the

thickness/cross-sectional area of the work piece is reduced by increasing length.

• SETTING DOWN : It is the local thinning operation

performed by the set hammer.


• BENDING : It is the operation by which the bend

may be either curve/sharp corner can be produced. Bending can be done using beak of anvil.

• PUNCHING : It is the process of making holes in the

work piece using punch & hammer.• WELDING : It is the process of joining two surfaces

of metal under pressure after they are heated to the welding temperature.

• CUTTING : It is a form of chiseling where a long

piece of stock is cut into several pieces of required length.


INTRODUCTION TO PRESS WORKING• Press working is a chip-less manufacturing process by

which various components are made from sheet metals. It involves the working of a sheet between two die. In press working, the upper die is called a punch. This process is also termed as cold stamping.

• The machine used for press working is called a Press. Press is a machine in which there are two or more slides, which move relatively to compress the material in the desired shape.


PRESS The main features of a press are:• A frame which support a ram or a slide and a bed, a source of mechanism for operating the ram in line with and normal to the bed.• The ram is equipped with suitable punch and a die block is attached to the bed.• A stamping is produced by the downward stroke of the ram when the punch moves towards and into the die block.• The punch and die block assembly is generally termed as a “die set” or simple as the “die”


CLASSIFICATION OF PRESS Different types of presses are classified based on:• Source of power : Mechanical, Electrical, Hydraulic, Pneumatic etcetera• Number of RAM : Single, Double, Multiple.• Method of transmitting power to RAM : Crank-shaft, Eccentric, Cam type or rack and Pinion type. • Design of frame : Solid frame, C Frame, Movable frame, Tie rod etcetera. • They are also classified based on the purpose and end usage.


PRESS WORKING OPERATIONSThe sheet metal operations done a press may be grouped into two categories.• Cutting operations• Forming operationsIn cutting operations the work piece is stressed by its ultimate strength. The stresses caused in the metal the applied forces will be shear stresses. The cutting operations include:(a)Blanking (b) Punching (c) Notching (d)

Perforating (e) Trimming (f) Shaving (g) Slitting (h)

LancingIn forming operations , the stresses are below the ultimate strength of the metal .There is no cutting of the metal but only the contour of the work piece is changed to get the desired product. The forming operations include:(b)Bending (b) Drawing (c) Squeezing



CUTTING OPERATIONS• Blanking: Blanking is an operation in which the blank obtained is the desired product, the rest portion is discarded.• Punching or Piercing: Punching is an operation in which the rest portion obtained is the desired product, the hole obtained is discarded.• Notching: This is cutting operation by which metal pieces are cut from the edge of the sheet , strip or blank.


• Perforating: This is a process by which multiple holes are very small and close together are cut in a flat sheet metal.• Trimming: This operation consists of cutting unwanted excess of material from the periphery of a previously formed component.• Shaving: The edge of a blanked part are generally rough, uneven and un square. Accurate dimensions of the part are obtained by removing a thin strip of metal along the edges.• Slitting: It refers to the operation of making incomplete holes in a work piece.• Lancing: This is a cutting operation in which a hole is partially cut and then one side is bent down to form a sort of tab. Since no metal is actually removed and there will be no scrap.


FORMING OPERATIONS• Bending: In this operation; the material in the form of flat sheet or strip is uniformly strained around a linear axis which lies in the neutral plane and perpendicular it’s the length wise direction of the sheet or metal.• Drawing: This is a process of forming a flat work piece into a hollow shape by means of a punch which cause the blank into a die cavity.• Squeezing: Under the operation, the metal is caused to flow to all portions of a die cavity under the action of compressive forces.

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Engineering

Forging & Press Working