Forging Processes

Open Die Forging

A hot forming process, which uses standard flat, "V" or
swage dies.
Impression Die Forging
Utilizes a pair of matched dies with contoured
impressions in each die. When the dies close, the impressions form a
cavity in the shape of the forging.
Ring Rolling
Forms axisymmetric shapes in a hot forming process. The
process begins with a "donut" shaped preform, which is made by
upsetting and piercing operations.
Open Die Forging
Impression Die Forging
Ring Rolling
Cold Forging
 Common Applications for Forgings
Aerospace
Aircraft Engines
Airframe and auxiliary equipment
Guided missiles and space vehicles
Automotive
Passenger cars
Trucks, busses and trailers
Motorcycles and bicycles
Bearings, ball and roller
Electric power generation/transmission
Industrial and commercial
machinery and equipment
Hand Tools
Industrial tools
Internal combustion engines
Metalworking and special industry
machinery
Mechanical power transmission
equipment, incl. bearings
Off-highway, equipment (construction,
mining and materials handling
Ordinance and accessories
Oil field machinery and equipment
Pipeline fittings
Plumbing fixtures, valves and fittings
Pumps and compressors
Railroad equipment and spikes
Rolling, drawing and extruding
equipment and tools for nonferrous
metals
Ship and boat building and repairs
Special industry machinery
Steam Engines and turbines
Steel works, rolling and finishing mills
 Types of forging
dies

Single-impression

Double-impression Interlocking
Design Rules for Parts Made From Impression Die Forgings

1 All features should be oriented so that

they can be formed in impressions
moving in opposite directions.
Features such as undercuts and holes
oriented other than in the direction of
forging are not typically forged and
must be fully machined.
2. Forging cost is minimized and
tolerances reduced when forging loads
are balanced, eliminating side loads on
the machine members that restrain the
dies
3 Sharp exterior corners require high forging
pressures to fill the corresponding die features.
Sharp interior corners (fillets) cause difficulties
in metal flow, and may require one or more
preform dies to attain, or may require additional
machining operations.
Therefore, radii should be as large as possible
consistent with functional and assembly
constraints.
Corner and edge radii should also be uniform to
minimize die sinking cost.

4 Draft angles should be the maximum allowable,

consistent with functional, assembly and weight
constraints.
For ferrous forgings, draft angles less than 5°
usually prohibit the use of hammers.
Dies installed in presses are usually equipped
with knock-out pins to eject the forging from the
cavity, and can produce forgings with little or no
draft.
As a general rule, less draft is required on the
outside of a feature than on the inside.
5. All datum targets and tooling points
should be located on features made in
the same die half, as illustrated in
Figure. The upper die half is preferred
since there is less contact between the
die and the forging, and consequently
less cooling.
6. Parts that are symmetrical about
an axis are the most economical
for upset forging.
Upsetting generally increases the
diameter of the beginning stock.
Therefore, the stock size will
generally correspond to the
smallest as-forged diameter. This
is the case for the flanged member
shown in Figure.
7. Where material properties are critical, it is important to specify
the required properties in all directions. This includes tensile
strength, yield strength, ductility and impact toughness. The
open die forger will design the forging process to develop grain
flow that will optimize the properties. Otherwise the forging
will be designed so that the grain flow follows the final contour
of the forging.
8. In view of the end use of the product, specify the
nondestructive testing methods to be employed and acceptable
methods for employing them.
9. Open die forging can be employed for a wide range of shapes.
For example, non-symmetrical shapes may be forged.
Design Rules for Parts Made by Cold and
Warm Forging
Commercially made cold forgings typically
weigh less than 23 kg (50 lb), although larger
forgings have been cold forged.

Net shape cold forgings should be considered for

products made in high volumes with surfaces
that are difficult or expensive to machine due
to geometric configurations.

Shapes that can be made by upsetting and

bending, such as bicycle pedal cranks, are
good candidates for cold forging.

Net or near-net shapes, such as tripot inner races

or universal joint crosses, can be
manufactured using cold or warm lateral
 Cold forgings do not require draft angles to release them from the
tooling.

Solid or tubular shaped products with either through or blind holes,

with net formed splines or other axial features, can be made by cold
forging.

When specifying blind holes, keep in mind:

• Holes that are deep in proportion to their diameter are difficult
to forge.
• Maintain uniform side wall thicknesses.
• The wall at the bottom of the blind hole should be at least as
thick as the side walls. (See Figure)

The hole on the left can be forged; the

one on the right will require a drilling
operation
Consult with the forger to determine the net shape capability, and
design net shape surfaces within those capabilities.
When designing solid shapes, minimize the difference between the
largest and smallest diameters of the part (See Figure A.)
Avoid undercut diameters in products to be cold forged. They can
be forged in some cases if the undercut is wide as illustrated in
Figure B.

Figure A
Figure B
Avoid extremely thin or thick wall sections when designing tubular
parts.

Undercuts can be forged in some cases if they are wide compared

with the diameter of the feature.

Avoid sharp corners: use fillets and radii.

 13-3
Powder Metallurgy .

Design considerations
Definition:
Powder metallurgy

 The process of making parts by

compressing and sintering
powders into shape
 Design considerations in
powder metallurgy:
 Ejection from the die
 Axial variations

 Corner reliefs
 Reverse tapers
Design considerations in
powder metallurgy:
 Holes at right
angles to the
direction of
pressing
 Undercuts

 Knurls
Design considerations in
powder metallurgy:
 Blind holes

 Flanges

 Corners
Design considerations in
powder metallurgy:
 Wall thickness
 Changes in
cross section
 Chamfers
13-4 Plastic Molded Parts
Design
considerations
Assemblies
Drawings

PhotoDisk
Quick Quiz
 What is the term for the process of
compressing and sintering
powders into shape to make parts?
 Powder
metallurgy
Design considerations in
molded parts:
 Shrinkage
 Section thickness
Gates
 Design considerations in
molded parts:
 Parting or flash line

 Fillets and radii

 Molded holes
Design considerations in
molded parts:
 Internal and external draft
 Threads
 Ribs and bosses

 Undercuts
 Assembly considerations
for molded parts
 Holes and threads
 Inserts

Press and shrink fits

 Heat forming and heat
sealing
 Assembly considerations
for molded parts
 Mechanical fastening

 Rivets
 Boss caps
 Adhesive bonding
 Assembly considerations
for molded parts
Ultrasonic bonding


 Ultrasonic staking
 Friction or spin welding