Introduction

Basic Knowledge
Forgings Significance, Design, Production, Application

Forgings Significance, Design, Production, Application

Directory
Page number
30 4 - 80 9 - 11 12 - 14 15 - 16 17 18 - 19 20 21 - 28 29 - 31 32 - 33 34 35 - 36 37 38 39 - 47 48 - 52 53 54 - 55 56 - 57 58 59 - 66 67 68 69 - 81 82 - 84 85 86 87 - 90 91 - 94 95 96 97 - 101 102

Subject
Preface Forging History Production Statistics Forging Materials Grain-Flow Tool Design and Profitability Accuracy of Forged Pars The most important forging processes Forging Machinery Automation Pre-Forming Ring Rolling Open-die Forging Special Process Hot Forging Special Process Warm Forging Cold Forging Process Stages Process Combinations Tools Heat Treatment Surface Treatment Quality Assurance and Material Testing Machining Process Forged parts in competition Diversity of Forms Applications Diversity in Forging Technology Optimization of Components Development Chain Simulation Sources of Illustrations and Information Imprint Bibliography Annex

NOTE: Please switch from standard view to screen presentation to be able to activate and use the links.

Forgings Significance, Design, Production, Application

Preface
Dear Readers, Ladies and Gentlemen, This presentation of the forging industry is designed to offer you an easily comprehensible insight into the highly interesting and, for the economy, tremendously important world of hot and cold forging. Even in the age of the Blackberry, IP-TV, Web 2.0 and all of the other colourful accomplishments that our modern world of the media presents us with every day, machine engineering and plant construction which is dependent on forged components by massive forming is and will remain one of the most important pillars of our present-day prosperity. Without high-strength, forged metal components, the economic and technical development that we have experienced over the last hundred years would not have been possible. Electricity and mobility in the form of motorised vehicles of all kinds are just two of the multifarious fields of application for modern forged parts. And also in the future, this technology will be used to an ever increasing extent: Thanks to worldwide economic growth in recent years, the export of forged parts from Germany to all parts of the world has been steadily increasing. Furthermore, the need to reduce CO 2 emissions will also boost the demand for hot and cold forged parts. The use of renewable energy by way of wind and hydroelectric power plants, economical combustion engines with high combustion efficiency and low frictional losses, as well as efficient dual clutch transmissions are merely a few of the many examples of environment protection which would be impossible without forged components. To enable the development and application of these often very complex and, technically speaking, highly demanding components, an increasing use of cutting edge computer technology and simulation software is being made in this branch of the industry. This presentation Basic Knowledge: Forgings Significance, Design, Production, Application is an open PowerPoint File. This means that it is possible for you to take elements from it for teaching purposes for your own presentation. By using the search function in PowerPoint, you are able to find the terms you need from the presentation in a few seconds. Besides the clear, summarised texts on the individual pages, many pages also show more detailed, full text descriptions that will provide you with further background information. Via directory you are able to switch within the subjects.

Hagen, 01/04/2011 Dr. Stefan Witt Chairman of the Board Industrieverband Massivumformung e. V. German Association of the Forging Industry
Back to directory >> Forgings Significance, Design, Production, Application 3

The art of forging is already 6000 years old

Forging is one of mankind's oldest technological processes. In 4000 BC metals were already being worked by smiths The first copper-alloys appeared around 2500 BC - we call this the Bronze Age

Sketch from the pictures in the grave of Rechmir, vizir in the 18th Dynasty (ca. 1450 BC)

Back to directory >> Forgings Significance, Design, Production, Application 4

Forging through the ages I

Between 700 and 500 BC iron replaced bronze. The smelting of the iron ore and the forging process were one unit until the 13th or 14th centuries.

Mediaeval smelting furnace with accompanying smithy. The furnace and the smith's fire both used charcoal as fuel in those days.
Back to directory >> Forgings Significance, Design, Production, Application 5

Water and steam replace muscle power

Water-powered iron hammer (ca. 1780)

Steam hammer "Fritz" in Essen (ca.1860)

Back to directory >> Forgings Significance, Design, Production, Application 6

The start of drop forging

The smiths of those days used hammers driven by transmission shafts to produce a wide range of forged parts for the railways, for the car industry and for agricultural machinery

View of the production area of the Schmiedag company in Hagen (ca.1910)

Range of products of the Schneweiss drop-forging works (ca.1910)

Back to directory >> Forgings Significance, Design, Production, Application 7

Development of forging technology

The development of drop forging made possible: - increasing batch sizes for the automotive industry - further development of and specialization in steel types - new technologies for tool production

- development of new machine types, new production processes and combinations of processes, and automation

View of a production facility with a linked automated forging line

Back to directory >> Forgings Significance, Design, Production, Application 8

Production figures - German forging sector

Production of forgings in 2010

Manufacturing group Drop forging industry Production in '000 tonnes 1280 Proportion in % 65

Flange manufacturers
Pipe-fittings producers Cold-forging manufacturers

68
95 175

3,5
4,8 8,9

Open-die forgers
Total forging production

350
1968

17,8
100

Almost two-thirds of the total forging output comes from the drop-forging sector.

Back to directory >> Forgings Significance, Design, Production, Application 9

Markets for forged products I

More than a third of all forged parts are exported. The automotive sector, together with system producers (tier one suppliers) receives more than 80% of the total production.

Others 5% Export 35% Domestic 65% Cars 34%

Mechanical engineering 10% System suppliers 36%

Trucks 15%

Percentages of steel forged parts delivered in 2009, in tonnes.

Back to directory >> Forgings Significance, Design, Production, Application 10

Current status of drop-forging technology

Germany is the number two producer world-wide. Production in 2008 was 3,000 000 tonnes.

Back to directory >> Forgings Significance, Design, Production, Application 11

Forgeable materials I
All metals and metal alloys, with very few exceptions, are suitable for forging. There is a range of more than 2,500 types of steel from which to choose to achieve the most economical production process.
Steel group Mild steels Heat-treating steels Case-hardening steels Standard DIN EN 10222-1 DIN EN 10250-1/-2 DIN EN 10083-1/-2/-3 DIN EN 10084

Nitriding steels
Steels for flame- and induction-hardening Ball- and rollerbearing steels High-temperature steels

DIN EN 10085
DIN EN 10083-1/-2/-3 DIN EN ISO 683-17 DIN EN 10269 DIN EN 10222-1/-2

Tough-at-lowtemperature steels
Stainless steels AFP-Steels

DIN EN 10269 DIN EN 10222-1/-2/-3

DIN EN 10222-5 DIN EN 10250-1/-4 DIN EN 10267

Forming characteristics of various material groups

Back to directory >> Forgings Significance, Design, Production, Application 12

Forgeable materials II
Steel group Mild steels Standard DIN EN 10222-1 DIN EN 10250-1/-2 DIN EN 10083-1/-2/-3 Application Machine parts with low dynamic loading and tensile strength requirements

Heat-treating steels

Machine parts and automotive components with higher dynamic or static loading such as steering knuckles, crank shafts, drive shafts and safety critical parts for automobiles and for use in cable cars and aerial ropeways. Case-hardened gearbox and drive-line components such as gears, shafts, toothed parts and wear-resistant forming tooling. Very high wear-resistance for chassis components, for tracked vehicles, conveyors for the mining industry, very large roller bearings with hardened tracks Special steels for hardened roller bearing rings and bodies. The steels achieve their very high hardness values by good through-hardening. High-alloyed steels for gas turbine engines, burners and industrial furnaces, forming tooling and dies. Machine parts for use at sub-zero temperatures, automotive components for use in extreme conditions, springs and applications with high dynamic loading. Fittings for the chemical and food industries, components for marine use, fittings for the building industry, cutlery and household wares, screws and fasteners and wire ropes for use in damp conditions. Application as with heat-treated steels but more cost-effective for engine and chassis components such as connecting rods, crankshafts, steering components, drive shafts and axles.

Case-hardening steels Nitriding steels Steels for flame- and induction-hardening Ball- and roller-bearing steels High-temperature steels

DIN EN 10084 DIN EN 10085 DIN EN 10083-1/-2/-3

DIN EN ISO 683-17

DIN EN 10269 DIN EN 10222-1/-2 DIN EN 10269 DIN EN 10222-1/-2/-3 DIN EN 10222-5 DIN EN 10250-1/-4 DIN EN 10267

Tough-at-lowtemperature steels Stainless steels

AFP-Steels

Back to directory >> Forgings Significance, Design, Production, Application 13

Forgeable materials III

For special applications, materials such as titanium, aluminium, nickel alloys and AFP-steels are also forged.

Medical components (Hip joints) in titanium

Front-wheel swing bearing

Heat-resistant turbine blades in nickel alloys

Connecting rods for truck engines in AFP steel (precipitation hardening ferritic-perlitic steel)

Back to directory >> Forgings Significance, Design, Production, Application 14

Grain-flow I
Grain-flow takes place during rolling through the longitudinal alignment of segregations in the steel. In an optimal forming process, this grain-flow is retained and runs parallel to the surface of the component.

Four cylinder crankshaft with counterweights

Optimal grain-flow increases the dynamic strength of the component

Back to directory >> Forgings Significance, Design, Production, Application 15

Grain-flow II
The grain-flow (with the segregated core of the raw material) runs from left to right through the component. Grain-flow breaking out of the side would result in an undesirable stress-raising notch effect.

Automobile gearbox shaft cold formed in two stages

The gear profile is milled in the two collars. In the area of the teeth, the grain-flow is perpendicular to the direction of the load

Back to directory >> Forgings Significance, Design, Production, Application 16

Tool design and profitability

The required quantities and batch sizes determine the form of the tooling and the most economical production process to use. Expensive tooling and/or several pre-forming tools are easier to justify for high quantities. The production costs can be lowered by process optimization and automation. The total costs can also be lowered by reducing the amount of machining required.
Small quantity
Low degree of adaptation to the finished form

Medium quantity
Moderate degree of adaptation to the finished form

High quantity
High degree of adaptation to the finished form

Costs

Finished part

Machining Production

Finished part

Machining

Finished part

Machining

Production
As-forged part Material Tooling As-forged part

Production
Material Tooling

As-forged part

Material Tooling

Dependence of the costs of forgings and of finished parts on the quantity produced
Back to directory >> Forgings Significance, Design, Production, Application 17

Accuracy of forged parts

= Achievable with conventional production equipment = Achievable using special methods or in exceptional cases

Generally, for steel drop-forgings the dimensional tolerances laid down in DIN EN 10243-1 apply. Closer tolerances can be agreed individually between manufacturer and customer. For steel open-die forgings, special tolerances apply.

Precision forged pair of bevel gears with helical teeth and clutch dogs

Back to directory >> Forgings Significance, Design, Production, Application 18

Accuracy of forged parts

The tolerances that are technically possible for forgings depend on the position of the dimension; thickness dimensions which are formed across the parting line of the dies require larger tolerances than height and diameter dimensions contained entirely in one die-half the complexity of the forging; here a distinction is made depending on the fine detail of the forging the weight and size of the forging ease-of-forging, depending on the type of material The calculation of tolerances is laid down in DIN EN 10243-1 Tighter tolerances are possible using extra measures and must be agreed with the manufacturer.
Back to directory >> Forgings Significance, Design, Production, Application 19

The most important forging processes

Five main methods are used in forging: - Drop-forging - Upsetting - Extrusion - Open-die forging - Ring rolling
Drop-forging
Punch Saddle Die Workpiece Workpiece Axial rolls Mandrel Gripper jaws Upper die

Upsetting punch

Lower die

Workpiece

Workpiece

Upsetting
Main roll

Workpiece

Saddle

Extrusion

Ejector

Open-die forging

Ring rolling

All hot-forming processes take place at around 1,200C

Back to directory >> Forgings Significance, Design, Production, Application 20

Forging machinery I
Three main types Of machine are used for Forging: - energydependant - press-forcedependant - machinestrokedependant

Main types of machine

energy-dependant

press-forcedependant

machine-stroke-dependant

with linear stroke

with rotary working motion

Double-acting hammers Counterblow hammers Screw presses

Hydraulic presses

Eccentric presses Crank presses Upsetting machines

Ring rolling Reducer rolling Cross rolling

Back to directory >> Forgings Significance, Design, Production, Application 21

Forging machinery II
Presses energy-dependant press-force-dependant machine-stroke-dependant

The machine types are shown depicting the limiting conditions at the end of the working stroke. Each machine type has its advantages and disadvantages and is specially chosen depending on the part to be produced.
Back to directory >> Forgings Significance, Design, Production, Application 22

Hammers for drop forging I

1 1 2

Power unit

Ram
Upper die Lower die Anvil block Vibration damper elements

2
3 4

3 4

5
6

5
6

The double-acting hammer (energy-dependant) is hydraulically or pneumatically driven.

To dampen the vibrations, the hammer is mounted on spring elements

Back to directory >> Forgings Significance, Design, Production, Application 23

Hammers for drop forging II

1 1 2

Drive

Ram
Upper die Hammer frame Lower die Lower ram Hydraulic ram clutch

2
3 4 5

3 4

5
6 7

The counterblow hammer is driven pneumatically ideal for large pieceweights

6 7

The counter movements of the ram reduce vibrations

Back to directory >> Forgings Significance, Design, Production, Application 24

Presses for drop forging I

8 6 9 1 2

Frame

Punch slide
Punch guide Screw spindle Spindle nut Clutch

3
4

7
4 5

5 6 7 8 9

Flywheel bearings
Spindle brake Hydraulic equipment Ejector Pneumatic

10
3 11 11

counterweight
10

The screw press is suitable for long runs and can be automated

A large amount of forming energy is available

Back to directory >> Forgings Significance, Design, Production, Application 25

Presses for drop forging II

1 5 2 3 4

Hydraulic cylinder

Ram
Table Machine frame Electric motors Walking beam automation

1
2

5
6

8 7 8

Forming station

Material feed

3
7

The hydraulic press offers a constant maximum press force over the whole stroke

It is particularly suited for hot- and cold-extruding with a long working stroke

Back to directory >> Forgings Significance, Design, Production, Application 26

Presses for drop forging III

5 9

3 7 8 1

2
4 10

The eccentric press is machine stroke dependant and readily automated at high rates of production (strokes per minute)

1 2 3 4 5

Frame Ram Connecting rod Ram guide Clutch and brake system

6 7 8 9

Counterweight Ram adjustment Reduction gearbox Double-helical gearing

10 Upper and lower ejector

Back to directory >> Forgings Significance, Design, Production, Application 27

Presses for drop forging IV

8 1

6
7 9 2 5

4
10

The wedge press is tip-resistant and is ideal for off-centre forging

Frame Ram Wedge Ram guide Clutch and brake system

Counterweight Ram adjustment Reduction gearbox

2
3 4 5

7
8 9

Double-helical gearing 10 Upper ejector

Back to directory >> Forgings Significance, Design, Production, Application 28

Automation of important forging equipment

1
3 8 2

5 6

Walking beam system

1 2 3

Tongs arm system

4 5 6

Feed gripper Power unit

Walking beam unit Press frame

1 2 3

Feed gripper Transport grippers

5 6 7

Tongs slide System drive unit

Transport
grippers

Lower die

Lower die
Tongs arms

Transverse slide
Press framer

Back to directory >> Forgings Significance, Design, Production, Application 29

Automated multi-die hot-forging presses

Multi-die presses for hot forging (e.g. Hatebur) are fully automatic in operation. The speed is continuously variable and large numbers of pieces can be produced

Automatic multi-die hot-forging press with inductive pre-heating equipment

Tool area of a multi-die hot forging press with four dies

Back to directory >> Forgings Significance, Design, Production, Application 30

Automated production line

A series of eccentric presses linked to form a production line using robots the operator is keeping an eye on the whole process

Back to directory >> Forgings Significance, Design, Production, Application 31

Pre-forming 1
1 10 9

7 3

1 Length compensation cylinder

6 Roll drive with automatic

backlash compensation

Reducer rolling, through the distribution of material, optimises flash and saves raw material when forging

2 Servo-controlled electric transverse feed

7 Water-cooled brake and

asbestos-free brake pads

Crank-rocker drive mechanism

4 Eccentric mounting of the lower roll for

adjusting the distance between rolls

8 Clutch with asbestos-free pads 9 Flywheel with large energy reserve

5 Feeder device to position the workpiece

between the grippers of the manipulator

10 Automatic rocker arm

Back to directory >> Forgings Significance, Design, Production, Application 32

Pre-forming 2

Cross-wedge rolling is suitable for parts with a circular cross-section and is used to distribute material in one production step. For simple shafts it can be suitable for the production of finished parts.

1 2 3

Roll segments Work rest

Machine frame
Electric motors

Back to directory >> Forgings Significance, Design, Production, Application 33

Ring rolling
Seamless rolled rings are typical products of the forging industry. Ring rolling can produce seamless rings with square and rectangular cross sections as well as rings with internal and/or external profiles. The largest diameter which can be produced today is approx. 8 metres
Typical radial-axial ring rolling machine

Back to directory >> Forgings Significance, Design, Production, Application 34

Open-die forging I
Open-die forging is the oldest method of forging. It is used for one-off workpieces, short production runs and for very heavy parts
1 3

2 4 5

Automated open-die forging using underfloormounted equipment with a freely movable manipulator

Open-die forging press with underfloormounted equipment and an integrated railmounted manipulator
1

Forging press
Workpiece Manipulator

Forging saddle
Forging saddle

2
3

Back to directory >> Forgings Significance, Design, Production, Application 35

Open-die forging II
Longitudinal forging machine with four radially-arranged tools.

The arrangement of the tooling on a longitudinal forging machine for high precision rotary swaging of hollow parts with an optimized weight

2
3 4 5

1 2 3
Back to directory >> Forgings Significance, Design, Production, Application

Manipulator
Forging tools Forging machine

4 5

Workpiece
Manipulator

36

Special forging processes

These special processes are largely used for the mass production of families of similarly shaped parts
Anvil plate Contact electrode Hydraulic cylinder Workpiece Lower die Upper tool

Workpiece

Electric upsetting

Die rolling

Roll segment

Base tool

Wobble bell

Tool segment

Upper die Workpiece Workpiece Roll segment

Workpiece

Lower die
Base tool

Tool segment

Tool segment

Cross-rolling

Wobble forging

Swaging

Back to directory >> Forgings Significance, Design, Production, Application 37

Special process warm forging

Shaft for a tripod CV-joint manufactured using a combination of warm forging and cold sizing.

A drive shaft component manufactured using a combination of warm forging and cold sizing. As-forged part on the left, finished part on the right

Back to directory >> Forgings Significance, Design, Production, Application 38

Cold Forging
Definition: Cold forging = no heating of the workpieces and/or forming starts at room temperature.
Most producing companies are medium-sized companies.

up to 49

employees

50 199 employees 200 399 employees 400 and more employees

Back to directory >> Forgings Significance, Design, Production, Application 39

Cold Forging

Cold forging Worldwide 2008

Cold forging Europe-wide 2008

450 North America

399 Europe 160 China 122 Japan 40 Russia 298 Germany 50 France

160 UK

25
17

Australia
India

122 Spain
19 Rest

Annual production in thousands of tons

Annual production in thousands of tons

German share Globally: 24.6%

German share Europe-wide: 74.7%

Back to directory >> Forgings Significance, Design, Production, Application 40

Cold Forging
Advantages Near-net-shape forming Higher dimensional accuracy than with forged parts Very high degree of material utilisation Difficulties Extensive treatment of the workpiece

Less degree of forming than with hot forming

Complex forms difficult to realise

No scaling
High surface quality High workpiece strength through strain hardening Expedient grain flow as with hot forming No heating necessary

Higher tool expenditure

Very suitable especially for large quantities

Back to directory >> Forgings Significance, Design, Production, Application 41

Cold Forging
Typical methods and special methods Essential cold forming processes are: Tapering, extruding, upsetting, thread rolling, and ironing

Forward extrusion

Drawing

Backward can extrusion

Rotary swaging

movable roll jaw

fixed roll jaw

Raw material on which thread is applied

Ironing

Upsetting

Thread rolling

Back to directory >> Forgings Significance, Design, Production, Application 42

Cold Forging
Exemplary parts

Gear shaft
5000g

Drive junction
(cardan shaft) |1000g

Shaft housing (car tie

rod) | 290g

Gearshift level
(PRINZ) | 209g

Steering fork
(automotive) | 160g

Pinion
(acrument) | 137g

Clutch wheel
(bicycle) | 18g

Dowel screw
(KAMAX) | 13g

Back to directory >> Forgings Significance, Design, Production, Application 43

Cold Forging
Special methods Hot forging High formability Cold forging High precision

Combination of hot and cold forming

Pinion cage Combination of hot and cold forming

Primary forming at high temperature allows high degrees of forming

Part-conform finished sizes and surface qualities can be achieved in cold state

The methods to be chosen depend on the process chain Criterion for an expedient combination: Mere cold forming would require at least one process annealing step Direct competition: hot forming and machining

Fixed joint Combination of semi-hot and hot forming

Back to directory >> Forgings Significance, Design, Production, Application 44

Cold Forging
Materials and machines Types of presses: Drive type: Mechanical presses Hydraulic presses Servomotor presses Number of steps: Multi-step presses Single-step presses Design: Horizontal Vertical
Hydraulic press

Coil www.asia.ru

Processable types of materials: Steel Non-ferrous heavy metals Aluminium Stainless steel

Blank forming: Sections Coils

Classic cold forming material: Preferably non-alloyed case hardening and tempering steels with a C-content of max. 0.5 % (alloy shares at most 5%).
Back to directory >> Forgings Significance, Design, Production, Application 45

Tools of a multi-stage press www. zeller-gmelin.de

Cold Forging
Process chain Forming mostly takes place in several stages

Pre-treatment

Annealing

Coating

Forming

Post-processing

Shearing Blasting

Lubricant carrier layer (e. g.: Zink phosphate) Lubricant (e. g.: soap, MoS2) New lubricant systems

Coating removal Annealing Machining Thread rolling

Back to directory >> Forgings Significance, Design, Production, Application 46

Cold Forging
Current trends and developments Function integration: Integration of additional functions in parts New, more solid materials Ready-to-fit parts Reducing the economic minimum quantity Phosphate-free forming / alternative lubricants

Back to directory >> Forgings Significance, Design, Production, Application 47

Processes prior to forging I

Depending on the hardness of the material, its cross-section and the cut-off rate required, various cut-off systems are used for making blanks .

Sawing offers the advantage of the greatest precision and the largest cross-sections, but has higher material wastage, longer cycle times and higher costs.

Cold shearing has the advantages of low material wastage and short cycle times. The disadvantage is that the cross-sectional area is limited (to max. 150mm)

Hot shearing is independent of material hardness and is well suited for integration into high speed automated forging lines.

Back to directory >> Forgings Significance, Design, Production, Application 48

Processes prior to forging II

Inductive heating equipment

Inductive heating of cut-off blanks to a forging temperature of approx. 1,250 C

Back to directory >> Forgings Significance, Design, Production, Application 49

Process stages in manufacture

Production stages of a drop-forged crankshaft form left to right: Steel blank Pre-formed blank Rough-forged part Finish-forged part Forging and trimmed flash Crankshaft

Lower rough forging die

Lower finish forging die

Trimming tool

Trimming punch

Back to directory >> Forgings Significance, Design, Production, Application 50

Process steps after forging

Flash and piercing-slugs are removed by trimming and holepiercing. Post-forging processes save material and processing costs, reduce the dimensional variation and make possible undercuts.
Forging with flash Trimming die Trimming punch Arm before bending Flash Forging Big and little ends in as forged condition Forging Arm after bending and sizing

Piercing punch Forging with inner flash Big and little ends punched to size

Forging
Before expanding

Piercing die

Forging
After expanding Forging

Internal flash

Trimming and piercing

Subsequent forming (e.g. bending, sizing, expanding)

Back to directory >> Forgings Significance, Design, Production, Application 51

Special process for post forming

The connecting rod big end is fractured in a defined way using a splitting wedge to give an exact fit this saves the sawing and milling operations. The individual fracture pattern is used to provide an exact fit between the two surfaces.

The breaking (cracking) of the big end is carried out by applying pressure to a splitting wedge

The pair of cracked surfaces are unique and offer a high degree of fitting accuracy with relatively little effort

Back to directory >> Forgings Significance, Design, Production, Application 52

Process combinations
The use of combinations of processes enables multi-axis forming to be carried out and thus complex geometrical forms to be manufactured

Shock absorber lugs: drop-forged and upset

Gear wheel with internal spline: warmforged and cold-sized; very high degree of accuracy on the flanks of the teeth

Carrying sleeve for a truck: drop-forged and hot-extruded; multistage forming

Trailer axle: dropforged and welded; light-weight design with a combination of different materials

Back to directory >> Forgings Significance, Design, Production, Application 53

Tooling for forging

For open-die forging, saddles with various different working surfaces are used. Dies have the "negative" form of the workpiece and can therefore only be used for specific forms Lower dies
Flat saddle

Single-impression die Pointed saddle

Multiple-impression die Forging

Multi-stage die Movable Die halves opened

Upper die Die-holder Rounded saddle Movable die halves closed

Die-holder

Ejector

Lower die

Ejector

Closed die Open-die forging Various forms of saddle

Back to directory >> Forgings Significance, Design, Production, Application

Die with several closure lines

Drop-forging: typical types of die

54

Toolroom: manufacture of dies and other tooling

The form of a die is produced either by spark-erosion or by high-speed milling. The surface of the form is treated is various ways to improve its life (e.g. by grinding, polishing, nitriding and/or hardchrome plating ).

Milling of the electrode

CAD design of the form geometry

CNC milling of the form

Spark-erosion of the die form Surface treatment of the die form

Finishing of the die form

Finished die

Diagram showing die manufacture

The milling head of the high-speed milling machine rotates at up to 40,000 rpm.

Back to directory >> Forgings Significance, Design, Production, Application 55

Heat treatment of forgings I

Normalising (N)

*Austenite formation and quenching Quenching and tempering (QT)

Heat-treatment from the forging heat

Ac3: temperature at which the transformation of ferrite into austenite on heating is completed Ac1: temperature at which the formation of austenite on heating commences RT: room temperature

Soft-annealing (A)

Schematic representation of heat-treatment processes used for steel drop-forgings

Back to directory >> Forgings Significance, Design, Production, Application 56

Heat treatment of forgings II

Controlled cooling from the forging heat, continuous cooling process

Controlled cooling from the forging heat (P), isothermal transformation left: diagram showing heat-treatment processes for steel drop-forgings right: diagram showing the most important heat Treatment processes for aluminium drop-forgings

Back to directory >> Forgings Significance, Design, Production, Application 57

Surface treatment I
After forging the workpiece is descaled by shot-blasting. The shot size is between 0.8 and 2.8mm

Steel wire pellets (1,400 - 2,000 N/mm2) or steel grit (45 - 50 HRC) are used as blasting media

Back to directory >> Forgings Significance, Design, Production, Application 58

Quality assurance for forged parts

The finished workpiece is checked dimensionally using a coordinate measurement machine. The measurements are made either on a sample basis or 100% for safety critical parts (e.g. for aircraft components).

The machine is calibrated using the yellow workpiece (the so-called setting gauge or reference part).
Back to directory >> Forgings Significance, Design, Production, Application

Diagram showing a quality control chart to demonstrate process stability

59

Non-destructive materials testing I

Magnetic-resonance testing: the raw material is excited by a magnetic field. Faults (resonances) show up on the VDU. Magna-Flux process: ferromagnetic particles align themselves preferentially along surface faults.

The lower green zigzag line on the VDU indicates the fault
Back to directory >> Forgings Significance, Design, Production, Application

When examined under UV light, the surface faults become visible

60

Non-destructive materials testing II

In non-destructive testing of materials the component remains intact and can be used further. This enables 100% testing to be carried out (e.g. for aircraft components)

Brinell hardness testing using a sphere and measuring the diameter of indentation (10; 5; 2.5 and 1 mm)
Back to directory >>

Vickers hardness testing using a Rockwell hardness testing using pyramid and calculating the area a cone and measurement of the of indentation depth of indentation

Forgings Significance, Design, Production, Application

61

Non-destructive materials testing III

Ultrasonic testing

This method is used for both magnetic and non-magnetic materials.

This material fault (chevron crack) was caused by the material flow being too rapid

Back to directory >> Forgings Significance, Design, Production, Application 62

Non-destructive materials testing IV

Ultrasonic testing VDU image

Back to directory >> Forgings Significance, Design, Production, Application 63

Non-destructive materials testing V

Dye-penetration testing (capillary process)

A special dye, which penetrates cracks, is applied to the workpiece. After rinsing and the subsequent application of a developer, the cracks become visible. This process is used for testing non-magnetic metals.

Back to directory >> Forgings Significance, Design, Production, Application 64

Destructive materials testing I

Destructive material testing for tensile strength and notch bar impact value is carried out on samples taken from batches of parts. The test specimens are made from finished components.

Tensile testing

Load-displacement diagram of a tensile test

Back to directory >> Forgings Significance, Design, Production, Application 65

Destructive materials testing II

The notched bar impact test is a destructive test. The test specimen is machined out of the finished component.

The notched test specimen has dimensions of 10 x 10 x 50 mm and is fractured by the pendulum In the notched bar impact test a pendulum is swung against the test specimen. The energy required (in Joules) is proportional to the difference between the heights of the pendulum H and h. This gives a measure of the toughness of the material.
Back to directory >> Forgings Significance, Design, Production, Application 66

Machining of forged parts

High-speed steel (HSS), tungsten carbide (TC) and ceramics are all used to make cutting tools. Cutting speed vc (m/min)
Turning Cutting tool material f = 0,2 mm f = 0,4 mm Drilling Cutting tool material f = 0,02 x d

Hardness HB

TC, uncoated
TC, coated

225
290 650 180 250

190
230 500 160 190

HSS, coated
TC, coated

25
90

190-220 ceramic TC, uncoated 220-250 TC, coated

HSS, coated TC, coated

18 70

ceramic

550
Milling cutter inserts

450
Threads fz = 0,25 mm 250 180 cutting tool material HSS, coated HSS, coated f = m (pitch) 10 8

Cutting tool material 190-220 220-250 TC, uncoated TC, coated

fz = 0,12 mm 300 200

Recommended cutting speeds for the machining of forgings

Back to directory >> Forgings Significance, Design, Production, Application 67

Forged components in competition

In comparison with its cast equivalent the forged full-floating axle shown here has superior material properties and high process stability.

The costs were reduced markedly by incorporating a forged part

The forged full-floating axle is cheaper, does not need subsequent hardening and tempering and has a reduced scrap rate.

Back to directory >> Forgings Significance, Design, Production, Application 68

Diversity of forms in automotive manufacturing I

In car manufacture special properties are required, which can be achieved using hot-, warm- and coldforging or a combination of several manufacturing steps.

Steel and aluminium chassis Engine parts are mostly made of components for car manufacture. hot-forged steel

Gear-box parts made of steel hot-forged and cold-sized

Back to directory >> Forgings Significance, Design, Production, Application 69

Diversity of forms in automotive manufacturing II

Improved accuracy and finer detail can be achieved using combinations of hot-, warm- and cold forming processes.

Drive-train and axle parts: hot-, warm- and cold-forged

Gear-box shafts are often cold extruded

Back to directory >> Forgings Significance, Design, Production, Application 70

Diversity of forms in automotive manufacturing III

The high torques in the gearboxes of today's diesel engines can only be transmitted by heavy duty forgings. The components are cold- or hotforged or made using a combination of processes.

1 Gear-wheels
3 2 Shafts 3 Parking lot 4 Planet-carrier

Section through a Mercedes-Benz 7G-Tronic automatic gearbox

Back to directory >> Forgings Significance, Design, Production, Application 71

Diversity of forms in automotive manufacturing IV

Forged parts meet high demands for fatigue strength, lightweight construction and cost-effective manufacture

1 2

Axle pivot

Axle drive shaft

Control arm Wheel carrier Differential

3
1 2 3 4 4 5

Mercedes-Benz Car, powered rear axle

Back to directory >> Forgings Significance, Design, Production, Application

72 72

Diversity of forms in automotive manufacturing V

Suspensions have to meet the criteria of driving dynamics, ride comfort, component size, weight and modularization (platform systems).

1 2 3

Upper transverse control arm

Lower transverse control arm Universal joint Achszapfen Left-hand wheel trunk Right-hand wheel trunk

4
5 6 5 6

Mercedes-Benz Car, non-driven front axle

Back to directory >> Forgings Significance, Design, Production, Application 73

Diversity of forms in automotive manufacturing VI

In vehicle construction, engineers are looking for the lightest possible designs. This saves fuel and CO2 emissions and improves comfort and driving dynamics. This component, optimised using FEM methods, Is made of aluminium The low unsprung weight increases sprung comfort

Back to directory >> Forgings Significance, Design, Production, Application 74

Diversity of forms in automotive manufacturing VII

Kurbelwelle

Pleuel

Suspension support, forged in aluminium

Four cylinder motor-cycle crank drive with integrated forged gear-wheels to drive and Control the camshaft

Back to directory >> Forgings Significance, Design, Production, Application 75

Diversity of forms in automotive manufacturing VIII

The valve drive has to withstand extremely high accelerations and temperatures. Forged components fulfil these requirements.

2 3

1
5 2 4 3 4 5

Rocker arm Push-rods - cold-formed parts Valve bridge Camshaft

Inlet and outlet valves

Four cylinder valve drive of a diesel engine

Back to directory >> Forgings Significance, Design, Production, Application 76

Diversity of forms in automotive manufacturing VIII(a)

In very highly stressed areas forged components improve operating safety.

1 Mount of support
2 Differential 3 Leaf spring holder 4 Gear wheels in differential

5 Propeller shaft
4 5 6 7 6 Axle drive shaft 7 Planetary gears

Double floating axle with dual tyres on a truck.

Back to directory >> Forgings Significance, Design, Production, Application 77

Diversity of forms in automotive manufacturing VIII(b)

1

In very highly stressed areas forged components improve operating safety.

1 Differential
2 Leaf spring holder 3 Cardan shaft 4

4 Flange for

cardan shaft

Double floating axle with dual tyres on a truck.

Back to directory >> Forgings Significance, Design, Production, Application 78

Diversity of forms in automotive manufacturing IX

The individual components of a cardan shaft have to transmit high torques and be maintenance-free at the same time.

1
2

Flange Cross pin Joint fork Hollow shaft Butt-welded joint fork

3
1 2 3 4 5 4 5

Cardan shaft with universal joints

Back to directory >> Forgings Significance, Design, Production, Application 79

Diversity of forms in automotive manufacturing X

1 2

Forged components are ideal for handling the extreme mechanical and dynamic loading on heavy construction machinery.
1
2

Blade hinge Cylinder eye Scarifier tooth Drive sprocket Track guide Track idlers

3
4 7 6 5 4 3 5 6

Bulldozer with scarifier Bulldozer with scarifier

Track links

Drive-sprocket segment
Back to directory >> Forgings Significance, Design, Production, Application 80

Diversity of forms in automotive manufacturing XI

1 4

2
3

5
6 8 9 7

Forged components have a long life and meet the high safety requirements of rail vehicles. On the left a wagon bogie. Lower pivot bearing Brake lever joint

1 2 3

Axle
Side bearer Slack adjuster Brake block slack adjuster Brake lever

3 1

10

4
5 6

2
8 10

7 8

Bow girder
Brake block shoe Wheel tyre

9
10

Back to directory >> Forgings Significance, Design, Production, Application 81

Use in pipe fittings

Valves are corrosion- and acidproof. They are used for liquid and gaseous media.

2
3 4 5

1
2 3

Handwheel Collar Neck Gland follower

4 5

Bonnet
Casing Flanges Seating ring Eyebolt

7
8

6 7

8
9

Left: Valve for direct welding into a pipeline Right: Valve with flanges for bolting
Back to directory >> Forgings Significance, Design, Production, Application 82

Use in aircraft manufacture

Alongside their use in jet engines, forged components are also used in highly-loaded areas such as wings, rudders, control surfaces and landing gear.
1

The four-engined Airbus A380 puts its trust in forging technology

1 3

Low pressure compressor Bladed disks

4

High pressure turbine blades

5

Turbine shaft

Turbine

Back to directory >> Forgings Significance, Design, Production, Application 83

Use in wind turbines

1 2 3 5 4 8 1 2 3 4 5

Drive shaft Generator Planetary gearing Blade adjustment. Rotor pitch Disc brake Connecting rings to steel tubular tower

6
7

Large roller bearing with azimuth adjustment

Blanks for gear-wheels, rolling and plain bearings

8 6 7

View into the nacelle of a modern wind energy plant

Back to directory >> Forgings Significance, Design, Production, Application 84

Diversity in forging technology

With the assistance of various forging and forming processes such as hot-, warm- and cold forging and their combinations, a large range and diversity of specialized components can be manufactured with piece weights ranging from a few grams up to several tonnes in the case of open-die forging.

97 percent of forged and formed parts are made of steel, but also aluminium and titanium as well as such non-ferrous metals as copper, brass and nickel alloys.
Back to directory >> Forgings Significance, Design, Production, Application 85

Optimization of components
FEM programs (finite element methods) offer the possibility of optimizing weight and geometry right at the design stage.

The illustration shows a steering arm with a generated FEM lattice grid

Back to directory >> Forgings Significance, Design, Production, Application 86

Development chain I
Design, toolmaking and production are closely associated with each other to fulfil the customer's requirements.

production/ machining

specifications/ loadcases

part development

process development part optimisation

Back to directory >>

A rear wheel carrier passes computer-aided through the stations above on its way from the specification through to production.
87

Forgings Significance, Design, Production, Application

Development chain II
Design, toolmaking and production are closely associated with each other to fulfil the customer's requirements.

Example: the customer gives the installation space and the required properties for an aluminium front wheel swing bearing for a car. From this a first model is made and from this the forging design is developed.
Back to directory >> Forgings Significance, Design, Production, Application 88

Development chain III

With the aid of design software (e.g. Catia, UG), the forging design is discretised according to the limiting stresses.

Back to directory >> Forgings Significance, Design, Production, Application 89

Development chain IV
Linear-elastic FEM-simulation showing the stresses in the component.

Back to directory >> Forgings Significance, Design, Production, Application 90

Simulation I
Simulation requires high-performance hardware for the very rapid calculation of the finite element simulation with the aid of a cluster.

Cluster of nine processor computers and one control computer

Back to directory >> Forgings Significance, Design, Production, Application 91

Simulation II
Using the material flow simulation, designers can already see in advance whether the material distributes itself optimally during the forging process.

Visible fault caused by lack of material or an unsuitable die-form

Visible lap caused by a fault in the form in the previous operation(s)

Back to directory >> Forgings Significance, Design, Production, Application 92

Simulation III
The material flow simulation enables designers to view the forging process and possible faults in the developed tooling.

Yoke during the forging operation

Gear shaft
Back to directory >> Forgings Significance, Design, Production, Application 93

Simulation IV
In addition, the tooling stress can be simulated in advance. The coloured gradation shows the relative or equivalent stress.

Back to directory >> Forgings Significance, Design, Production, Application 94

Sources of illustrations and information

We would like to thank the following companies for their great help in providing illustrations and technical information: Acument Global Technologies, Inc. BMW AG Bombardier AG BPW AG Buderus EdelstahlwerkeSchmiedetechnik GmbH Caterpillar AG CDP Bharat Forge GmbH Dango & Dienenthal GmbH Daimler AG FEMUTEC / simufact engineering GmbH GKN GmbH Hatebur AG Hammerwerk Fridingen GmbH Hirschvogel Automotive Group Kamax-Werke Karl Diederichs KG Lasco Umformtechnik GmbH Mahle Brockhaus GmbH Mller-Weingarten AG Pratt & Whitney Presswerk Krefeld GmbH & Co. KG Prinz Verbindungselemente GmbH Ruchle GmbH + Co. KG Schubert Maschinen und Anlagen GmbH Schuler Group Siepmann Persta GmbH SITEMA GmbH & Co. KG SMS Group ThyssenKrupp Gerlach GmbH ThyssenKrupp Presta AG Volkswagen AG Zeller + Gmelin GmbH & Co. KG

Copyright 2011. All shown images, photos and texts are copyrighted. Partial reproduction of any contents only permitted by referencing the source. Infostelle Industrieverband Massivumformung e. V., Goldene Pforte 1, 58093 Hagen, Deutschland. Our website: www.metalform.de
Back to directory >> Forgings Significance, Design, Production, Application 95

Imprint
Editor Infostelle Industrieverband Massivumformung e. V. Editorial office and responsible for production: Infostelle Industrieverband Massivumformung e. V. Manuscript Ing. Horst Apholt VAT-no.: DE 125 127 673 Print-no. BW-411 Printed in Germany ISBN: 978-3-923726-26-9 The presentation is copyrighted. Partial reproduction of any contents only permitted by referencing the source. The publications of the Infostelle Industrieverband Massivumformung e. V. are based on the group research of the companies affiliated under the Industrieverband Massivumformung e. V. organisation.

Layout Peter Kanthak Freelance designer, Wickede

Publisher Infostelle Industrieverband Massivumformung e. V. Goldene Pforte 1 58093 Hagen Germany Phone: +49 23 31 9588-30 Fax: +49 23 31 9587-30 E-mail: orders@metalform.de Website: http://www.metalform.de

Image sources: The following companies have supported this presentation by providing source material:

Back to directory >> Forgings Significance, Design, Production, Application 96

Bibliography
Historical development Pischel, H.: Geschichte des Massiv- und Blechumformens. Krefeld: K. Dannat 1987 Sonnenschein, F.H.: Die Technikgeschichte des Schmiedens. Technische Kulturdenkmale 14 (1985) S. 12/17 Layout of forgings

DIN 7523: Schmiedestcke aus Stahl; Teil 2_09.86: Bearbeitungszugaben, Seitenschrgen, Kantenrundungen, Hohlkehlen, Bodendicken, Wanddicken, Rippenbreiten und Rippenkopfradien
DIN 7527: Schmiedestcke aus Stahl; Teil 1_10.71: Bearbeitungszugaben und zulssige Abweichungen fr freiformgeschmiedete Scheiben Teil 2_10.71: Bearbeitungszugaben und zulssige Abweichungen fr freiformgeschmiedete Lochscheiben Teil 3_10.71: Bearbeitungszugaben und zulssige Abweichungen fr nahtlos freiformgeschmiedete Ringe Teil 4_01.72: Bearbeitungszugaben und zulssige Abweichungen fr nahtlos freiformgeschmiedete Buchsen Teil 5_01.72: Bearbeitungszugaben und zulssige Abweichungen fr freiformgeschmiedete, gerollte und geschweite Ringe Teil 6_02.75: Bearbeitungszugaben und zulssige Abweichungen fr freiformgeschmiedete Stbe

v. Wedel, E.: Die Geschichtliche Entwicklung des Umformens in Gesenken. Dsseldorf: VDI-Verlag 1960

Branch overview Vieregge, K.: Gesenkschmieden in Deutschland im Zeichen des Wandels. Umformtechnik 27 (1993) 3 Voigtlnder, O.: Perspektiven der Massivumformung in den 90er Jahren. Werkstatt und Betrieb 121 (1988) 7. S. 561/567

Back to directory >> Forgings Significance, Design, Production, Application 97

Bibliography
DIN EN 10 243: Gesenkschmiedeteile aus Stahl Teil 1_12.95: Warm hergestellt in Hmmern und Pressen Matoleranzen Deutsche Fassung EN10 243-2: 1995 Production of forgings Dahme, M. und Hirschvogel, M: Mglichkeiten und Grenzen der Kalt-, Halbwarm- und Warmumformung. Werkstatt u. Betrieb 124 (1991), S. 865/868 Dser, R.: Gesenkwalzen Ein Maximum an Przision bei einem Minimum an Material- und Energieeinsatz. Umformtechnik 26 (1992) 1, S. 33/40

DIN 17 864: 02.93: Schmiedestcke aus Titan und Titan-Knetlegierung (Freiform- und Gesenkschmiedestcke)

DIN Normenheft 7: Anwendung der Normen ber Form- und Lagetoleranzen in der Praxis. 4. Auflage Berlin und Kln; Beuth-Verlag 1987 Breuer, H.-W.: Gestaltung beanspruchungs- und fertigungsgerechter Schmiedeteile. Konstruktion 43 (1991) S.285/291 Dahme, M. u.a.: Gemeinschaftliche CAD/CAM- Entwicklungen: Basis fr Simultaneous Engineering. Schmiede-Journal (1995) September S. 17/18

Back to directory >> Forgings Significance, Design, Production, Application 98

Bibliography
Elsinghorst, <<D.: Neues Maschinenkonzept: Przisions-Schmiedehammer. Schmiede-Journal (1997) September, S.26/28 Groene, S.: Axiales Gesenkwalzen ein Verfahren der Warmformgebung zur Herstellung von rotationssymetrischen Schmiedeteilen fr die Kraftfahrzeugindustrie, Thyssen Techn. Ber. 18 (1986) 2, S. 353/360 Jung, H.: Erhhung der Fertigungsgenauigkeit nach dem Schmiedeprozess durch Warm- und Kaltprgen, VDI-Z 133 (1991) 11, S. 49/56 Knig, W. und Klocke, F.: Fertigungsverfahren Bd. 4 Massivumformung Dsseldorf VDI-Verlag 1995 Knig, W. und Klocke, F.: Fertigungsverfahren 4 - Umformen Springer-Verlag 2006 Krner. E. u.a.: Mglichkeiten des HW-Fliepressens in Kombination mit dem Kaltfliepressen. Symposium Neuere Entwicklungen in der Massivumformung 28./29.05.91 Fellbach. Lange, K. und Meyer-Nolkemper, H.: Gesenkschmieden 2. Auflage Berlin, Heidelberg New York: Springer-Verlag 1977 Lange, K. (Hrsg.): Umformtechnik Bd. 2, Massivumformung. Berlin, Heidelberg, New York: Springer-Verlag 1988 Metals Handbook: Vol. 14, Forming and Forging 9. Ed. Metals Park (Ohio): American Soc. for Metals 1988 Schiller, w.: Wirtschaftliches Fertigen durch gratloses Schmieden Kostenvorteile, Industrie-Anzeiger 110 (1988) 5, S. 34/36 Schuler GmbH (Hrsg.): Handbuch der Umformtechnik. Berlin, Heidelberg: Springer-Verlag 1996 Vogt, H.J.: Gesenkschmieden und Schweien. Der Konstrukteur 10 (1979) 11, S. 41/51

Material properties
DIN-Taschenbuch 218: Wrmebehandlung metallischer Werkstoffe, Normen. 2. Auflage Berlin und Kln: Beuth-Verlag 1989

Back to directory >> Forgings Significance, Design, Production, Application 99

Bibliography
DIN-Taschenbuch 401: Stahl und Eisen; Gtenormen 1, Allgemeine Normen, Berlin, Wien, Zrich: Beuth-Verlag 1993 Stahleisen-Liste (Hrsg. VDEh): 9. Auflage Dsseldorf: Verlag Stahleisen 1994 Stahlschlssel: 18. Auflage Dsseldorf: Verlag Stahleisen 1998 Bruer, G.: Die Qualitt von Schmiedeteilen sichern. VDI-Z 132 (1990) 4, S. 125/128 Herbertz, R.: Qualittssicherung fr den Schmiedeprozess. In: Ber. Aus Forsch. und Entwicklung, Hagen: Industrieverband Deutscher Schmieden e.V. (Hrsg.) 1992

Mscher, G. und Schmidt, J.: Schmiedeteile aus AFP-Sthlen. Erfahrungen bei der Anwendung in Kraftfahrzeugen. VDI-Z 133 (1991) 4, S. 124/131
Masing, W. (Hrsg.): Handbuch Qualittsmanagement. 3. Auflage Mnchen: Carl Hanser Verlag 1994 Schle, W. und Huchtemann, B: Entwicklungsstand der ausscheidungshrtenden ferritischperlitischen (AFP-)Sthle mit Vandium-Zusatz fr eine geregelte Abkhlung von der Warmformgebungs-Temperatur. VDI-Ber. Nr. 774, Dsseldorf: VDI-Verlag 1989 Spitzer, H.: Maschinenbausthle-Entwicklungstendenzen und Normung. Umformtechnik 27 (1993) 1, S. 39/45

Broszeit, E. und Steindorf, H.: Mechanische Oberflchenbehandlung, Festwalzen, Kugelstrahlen, Sonderverfahren. Oberursel: DGM Informationsgesellschaft 1989
Grubisic, V. und Sonsino C.M.: Einflugren der Betriebsfestigkeit geschmiedeter Bauteile. VDI-Z 134 (1992) 11, S. 105/112

Harms, w.: Qualittssicherung fr den Schmiedebetrieb umfasst die ganze Fertigung vom Entwurf bis zum Versand. Maschinenmarkt 97 (1991) 25 S. 32/35

Sonsino, C.M. und Kaufmann: Einflsse auf die Schwingfestigkeit von Gesenkschmiedeteilen. VDI-Z 133 (1991) 4, S. 131/143

Back to directory >> Forgings Significance, Design, Production, Application 100

Bibliography
Winkler, H.: Wirtschaftliches Spanen von Schmiedeteilen in der Praxis. Hagen: Informationsstelle Schmiedestck Verwendung 1988 Breuer, H.-W.: Weiterentwicklung von Achsschenkel fr Nutzfahrzeuge. Schmiede-Journal (1995) Mrz, S. 18/19 Jung, H.: Gesenkschmiedestcke fr Bergbaumaschinen. Bergbau 32 (1981) 6, S. 312/318 Jung, H.: Gesenkschmiedestcke fr Getriebe und Kupplungen. VDI-Z 123 (1981) 11, S. 584/588 Schmieder, F. und Kettner, P.: Fertigung von Getriebe-Hohlwellen durch Massivumformung. Konstruktion 48 (1996) S. 402/406 Westerkamper, Ch. und Weimann, G: Przisionsumformung eine Schlsseltechnologie fr die Antriebstechnik. VDI-Z 9 (1997) S. 72/74 N.N.: Schmiedestcke im Maschinen- und Anlagebau. Hagen: Informationsstelle Schmiedestck Verwendung 1981

N.N.: Moderne Methoden der Qualittssicherung in der Umformtechnik. Umformtechnik 24 (1991) 4, S.69/76
N.N.: Praktische Wrmebehandlung. 2. Auflage Hagen: Industrieverband Deutscher Schmieden e.V. (Hrsg.) 1997

Examples of application of forgings

Adolf, W.W.: Entwicklungen bei Getriebewellen fr Fahrzeuge. Schmiede-Journal (1995) Mrz, S. 15/17 Adolf, W.W.: Kurbelwellen fr Straenfahrzeug-Motoren. Schmiede-Journal (1994) Mrz, S. 13/16

Back to directory >> Forgings Significance, Design, Production, Application 101

Annex

Manufactures of hot and cold forgings

The actual delivery facilities of the member companies within the Industrieverband Massivumformung e. V. you can find in our six different manufacturer lists (Drop-forged parts, upset forged parts, hot extruded parts, cold extruded parts, open-die forged parts, rolled rings).

The manufacturer lists can be downloaded free of charge (pdf data) on the internet:

www.metalform.de

Back to directory >> Forgings Significance, Design, Production, Application 102