MDB3073

Manufacturing Technology 2

Metal Forming-Forging of Metals

Forging

Forging is the making of parts where plastic

deformation takes place by compressive forces.
Can be carried out at room or at elevated temperature.
Type of forging:
Open Die-Forging
Impression Die-Forging
Closed Die-Forging

Open-die forging
Involves placing a solid cylindrical workpiece between
two flat dies and reducing its height by compressing it.
Deformation is at the dieworkpiece interfaces.

Homogeneous
Deformation

Non-homogeneous
Deformation

Open-die forging
Barreling
Caused by frictional forces at the dieworkpiece
interfaces and upsetting of hot workpieces between
cool dies.
Deformation throughout the specimen can be
nonuniform or inhomogeneous.
Minimized by lubricant

Open-die forging

Cogging (drawing out) operation

Open-die forging

Under ideal conditions solid cylinder deforms uniformly,

known as homogeneous deformation.
Reduction in height is defined as
Engineering and true strain is
e1

h0 h1
h0

h0

h1

1 ln

h0 h1
100%
h0

Open-die forging
Forces and work of deformation under ideal conditions
If friction is zero, normal compressive stress on cylindrical
specimen is uniform and at level Y.
Ah
The force at any h1 is F YA1 where A1 h0 0
1

Ideal work of deformation is

Work Volume d
0

With a true stress true-strain curve,

The expression for the work done is

K n and F Y f A1
1

Work Volume Y 1

where Y

K n d
0

K 1n

n 1

Open-die forging
Homogeneous Deformation
If a solid cylindrical workpiece is placed between two flat platens and an
applied load P is increased until the stress reaches the flow stress of the
material then its height will be reduced from initial value of ho to h1. Under
ideal homogeneous condition in absence of friction between platens and work,
any height reduction causes a uniform in-crease in diameter and area from
original area of Ao to final area Af.

The load required, i.e. the press

capacity, is defined by
P = YfAf
Yf is flow stress

Homogeneous deformation

Open-die forging
Non-homogeneous Deformation
In practice, the friction between platens and workpiece cannot be avoided and
the latter develops a barrel shape. This is called inhomogeneous
deformation and changes the load estimation as follows

Inhomogeneous
deformation with
barreling of the
workpiece

Impression Die-Forging

Workpiece acquires the shape of the die cavity while

deformed between the closing dies.
Quality, dimensional tolerances, and surface finish of
forging depend operations performance and control.

Impression Die-Forging

Standard terminology of a forging die

Example for forging operations

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

Impression Die-Forging
Impression-die forging
Forging force F can be estimated by

F K pY f A

Where Y is flow stress,

K is multiplying factor, A is area

Closed Die-Forging/Precision Forging

In true closed-die forging, flash does not form (hence

the term flashless forging), and the workpiece
completely fills the die cavity.
Figure below shows the comparison of (a) closed-die
forging with flash and (b) precision or flashless forging
of a round billet.

Closed Die-Forging
Precision forging
Parts formed is close to the final desired dimensions.
Aluminium and magnesium alloys are suitable as forging
loads as temperatures are low and they have a good
surface finish.
Steels and other alloys are more difficult to precision
forge.
Advantages are less machining involved and part is closer
to final shape.

Forging defects

1.
2.
3.
4.
5.

Defects can be caused by the material flow patterns in the

die cavity.
Excess material in the web buckle and develop laps
Web is too thick internal cracks
Size of die radii formation of defect
Grain-flow pattern rough surfaces
Temperature variations Strength and ductility varies

Examples of defects in forged parts.

(a) Laps due to web buckling during forging; web thickness should be
increased to avoid this problem.
(b) Internal defects caused by an oversized billet; die cavities are filled
prematurely, and the material at the center flows past the filled regions as
the dies close.

Die design
Design of forging dies depends on:
a) strength and ductility of the workpiece material
b) sensitivity to strain rate and temperature
c) frictional characteristics
d) forging temperature

Die design
Die materials
Must have strength and toughness, hardening ability,
resistance to mechanical, thermal shock and wear.
Selection depends on size of the die, properties of
workpiece, complexity of shape, forging temperature and
type of operation.
Tool and die steels containing Cr, Ni,Mo and V
Forging temperature and lubrication
Lubrication affects friction,
wear and flow of metal into
the die cavities.

Equipment
Forging equipments include:
a/b) Mechanical presses
c) Screw presses
d) Hydraulic presses
e) Hammers

Thank you