Manufacturing Process – 2 (2141908)

Forging Process

Prepared by :

Unziya Abhi (150123119052)

Introduction of forging

• Forging process is where workpiece is shaped by compressive forces applied through dies and tooling

• Forging operations produce discrete parts

• Forged parts have good strength and toughness, and are reliable for highly stressed and critical applications

• Forging can carry out at room temperature (cold forging) or at elevated temperatures (warm or hot forging) depending on the homologous temperature

Classification of forging

A. According to source of energy :

(i) Hand forging

(ii) Machine forging

B. According to type of die :

(i) Open die forging

(ii) Close die forging

C. According to application of pressure :

(i) Drop forging

(ii) Press forging

(iii) Machine forging

(iv) Impact forging

D. According to forging machine

(i) Hand forging

(ii) Machine forging

(iii) Press forging

(iv) Roll forging

Application Of forging

• Cutting tools , agriculture tools, machine parts

spring, hook, nails, screw, pin, handle etc.

• Furniture manufacturing.

• Home Appliance and scientific products.

• Building materials like handle, bolt, hinze, etc.

• Military product.

• Aircraft and misile peoducts.

Advantages Of Forging

• Grain structure refinement of metal.

• Time and labour cost is minimum because of

precision in work piece

• Machining is not required so cost is minimum.

• Better surface finish.

• Higher production rate.

• Product will defect free , defect like porosity ,

blow hole and crack is minimum.

Limitation of forging

• Higher tolerances is provided.

• Some of the metals cannot be forged.

• Simple product are manufactured.

• Under cut and holes are difficult to manufacturing

Hand forging • Compression of workpart between two flat or simply shaped dies

• Similar to compression test when workpart has

• cylindrical cross section and is compressed along its axis or its sides

• Deformation operation reduces height and increases diameter of

work

• Common names include upsetting or cogging

Impression die forging

• This process used for intricate and complicated

components where precision is highly requirement.

• One part is attached with machine ram and second part

is attached with anvil.

• Complicated shapes can not be produced in single

stroke under this process.

Drop forging

• Apply impact load (falling mass) against workpart

Potential - Kinetic -Deformation Energy

• Two types:

• Gravity drop hammers - impact energy from falling

weight of a heavy ram

• Power drop hammers - accelerate the ram by pressurized

air or steam

• Disadvantage: impact energy transmitted through anvil

into floor of building, Noise

• Commonly used for impression-die forging

Drop forging

Upsetting forging • More parts produced by upsetting than any other forging

operation

• Performed cold, warm, or hot on machines called

headers or formers

• Wire or bar stock is fed into machine, end is headed,

then piece is cut to length

• For bolts and screws, thread rolling is then used to form

threads