Metal Rolling

Metal Forging

Prof. K.N.WakchaureDept. of Mechanical EngineeringSRES COLLEGE OF ENGINEERING, KOPARGAON

Metal forgings can be small parts, or weigh as much as 700,000 lbs. Products manufactured by forging in modern industry include critical aircraft parts such as landing gear, shafts for jet engines and turbines, structural components for transportation equipment such as automobiles and railroads, crankshafts, levers, gears, connecting rods, hand tools such as chisels, rivets, screws, and bolts to name a few. The manufacture of forging die and the other high costs of setting up an operation make the production of small quantities of forged parts expensive on a price per unit basis.

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Heading Or Upset ForgingHeading or upset forging is a process by which stock, (typically cylindrical), is upset at its end in order to increase the cross section of the material in this area. This metal forging process may be hot, but is often a cold working operation. Cold working will take advantage of the strengthening of the material in the region worked.

Heading Or Upset Forging

Metal PiercingPiercing is a metal forging technique that is often performed as an auxiliary process in conjunction with other forging processes, in the manufacture of a part. It can be used to create a cavity or hole in the work piece

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Metal SizingSizing is a metal forging process that is used mainly to finish work that has already been manufactured. It is a cold forming process. Metal sizing uses a lot of force over a short distance, producing very accurate dimensions in the finishing of these parts. This manufacturing technique can also be used to create work with excellent surface quality.

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Metal Ball ForgingThe ability to manufacture metal spheres with very accurate dimensions and surface quality is important in modern industry. One of the main applications of these metal balls is for use as ball bearings. Ball bearings are widely used in mechanical systems involving the translation of motion.

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Ring ForgingSeamless metal rings of different sizes are commonly manufactured in modern industry for various applications, such as parts for machine tools, rockets, turbines, pipes, and pressure vessels.

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RivetingRiveting is a forging process that may be used to join parts together by way of a metal part called a rivet. The rivet acts to join the parts through adjacent surfaces. A straight metal piece is connected through the parts. Then both ends are formed over the connection, joining the parts securely.

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Metal CoiningMetal coining is a forging process by which very fine and intricate details can be created on the surface of a work piece. Coining may be used to control surface quality and detail on parts. Metal coining is often a finishing process for manufactured products.

TrimmingTrimming is a manufacturing process that is used as a finishing operation for forged parts, in order to remove flash.

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Analysis of Open Die Forging

True strain

Force Required

Flow Stress

If effect of frictional force is considered,

Forging shape factor

Problems