Production Techniques I

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Pilani Campus
Outline

Forging

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Types of forgings

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Strip Forging

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Assumption
– forging force”f “attains its maximum value at the end of the
operation
–  is constant
– variation of stress field along y-axis is negligible
– plane strain case
– entire w/p is plastic in state during the process

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Let at any instant the thickness of the element is “h” and
width is “2l”
Consider an element of width “dx” at a distance “x” from
origin.
Consider the equilibrium of the element in “x”direction.

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h d x  2 dx  0................(1)

[ now let x and  p are principal stresses

it being a case of plane area
  2  ( 1  p ) / 2
apply VON MISES criteria ,
p   x  2k ]

dp  d x ..............( 2)
puting in (1)
 h dp  2 dr  0
dp  ( 2 / h ) dx..................(3)
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Now as we move along the x- axis from origin,
the friction stress are increasing and when
(say) it reaches a value equal to shear yield
stress and it remains constant then after. In
other words from

x  0 to x  x s , we have a sliding / non  sticking zone

x  x s to x  l , we have a sticking zone

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FOR SLIDING ZONE ( x  0 to x  x s )
 p
equ(3)becomes
dp  (2p / h )dx
dp / p  2x / h  c1
to find c1
from equ(2) at x  0(  0), p  2k
 c1  ln 2k
 ln( p / 2k )  2x / h
or p / 2k  e 2 x / h
p1  2ke2 x / h .......... (4)
FOR STICKING ZONE
againu sin g equ(3)
dp  2 / hdx
[ we havex  x s ,  p s  k ]
 putingτ  k in aboveequ.and integrating, we have
p  (2k / h ) x  c2. .......... .....( 5)
to find cons tan tc2
x  xs , p  ps
p s  ( 2k / h) x s  c 2
c 2  p s  ( 2k / h) x s
now u sin g equ(4), p s  2ke2  / hxs
 c2  2k[e 2 xs / h  x s / h]
0 xl
p  2k[e 2 xs / h  ( x  x s ) / h]......... (6)
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TO FIND dx  xs ,
  ps  k  ps  k / 
puting this in equ (4), weget
ps  k /   2ke[ 2 xs / h ]
1 / 2   e 2 xs / h
or 2 xs / h  ln( 1 / 2  )
xs  h / 2  ln( 1 / 2  )
puting xs in equ (6), we get
p  2k[e ( 2  / h )( h / 2  ) ln(1/ 2  )  1 / h{x  h / 2  ln( 1 / 2  )}]
 2k[1 / 2   1 / h{x  h / 2  ln( 1 / 2  )}]
p2  2k[1 / 2 {1  ln( 1 / 2  )  x / h}]............(7) xs  x  l
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total forging force/ unit length
f  2[  p1dx   p 2dx]
xs l

0 xs

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DISC FORGING

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Let in a typical open die forging of a disc as shown in
figure, thickness and force at the end of the operation
are ‘h’ and ‘F’ respectively:
Consider an elemental disc subtending an angle ‘dθ’ at the
centre, between radii ‘r’ and ‘r + dr’.
Considering the radial equilibrium of strip,
( r  d r )( r  dr)d .h   r rd .h  2  dr.h sind / 2  2 .rddr  0
For the cylindrical symmetry (Assumption)    r

Now neglecting the higher order term

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 r rd .h  d r rd .h   r rd .h  2rddr  0
d r .h  2dr  0 ______________________________________(1)

Let ,  r ,   and p are Pr incipal Stresses

Therefore , Putting these valuesin eq n
( 1   2 ) 2  ( 2   3 ) 2  ( 3   1 ) 2  6k 2
We get
 r  p  3k ________________________________________(2)

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or
d r  dp
Put in eq n (1)
hdp  2dr  0 ________________________________________(3)

Let rs is the radius beyond which sliding takes place

i.e.
rs  r  R _______ sliding zone
0  r  rs _______ sticking zone

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For Sliding Zone :
  p
n
Put in eq (3)
hdp  2pdr  0
dp / p  (2 / h)dr
Integrating ,
ln p  (2 / h)r  C1
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 To find C1
r  R,  r  0,
Therefore from eq n ( 2)
p 3k
ln( 3k )  ( 2  / h) R  C1
or C1 /( 3k )  e ( 2  / h ) R
or C1  3k e ( 2  / h ) R
Hence , ln p  ( 2  / h) r  ln  3k e ( 2  / h ) R 
or p sl  3k e ( 2  / h ) R . e  ( 2  / h ) r

psl  3k e( 2  / h)( R  r ) ___________________________(4) rs  r  R

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For Sticking Zone :
At r  rs ,   k , also   p s
Putting,   k in eq n (3)
hdp  2kdr  0
or dp  (2k / h)dr
Integrating , p  (2k / h)r  C 2 ________________________(5)

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To Find C 2 :
At r  rs , p  ps
Putting in eq n (5),
p s  (2k / h)rs  C 2
or C 2  p s  (2k / h)rs
From eq n (4), by putting r  rs and put the valuein aboveeq n
C 2  3k e ( 2  / h )( R  rs )  (2k / h)rs
Putting C 2 in eq n (5), we get
p  (2k / h)r  (2k / h)rs  3k e ( 2  / h )( R  rs )
p  (2k / h)( rs  r )  3k e ( 2  / h )( R  rs ) _______________________(6)
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To Find rs :
At r  rs ,   k  p s
or ps  k / 
Putting this in eq n ( 4)
k/  3k e ( 2  / h )( R  rs )
e ( 2  / h )( R  rs )  1 / 3
(2  / h)( R  rs )  ln(1 / 3 )
R  rs  (h / 2  ) ln(1 / 3 )
rs  R  (h / 2  ) ln(1 / 3 )
Putting, rs valuein eq n (6)
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  
p 2  (2k / h) R  (h / 2 ) ln( 1 / 3 )  r  3k e ( 2  / h ) R R  ( h / 2  ) ln(1 / 3 ) 

 (2k / h)R  (h / 2 ) ln( 1 / 3 )  r   3k e ln(1 / 3 )

 (2k / h)( R  r )  (2k / h)( h / 2  ) ln( 1 / 3 )  3k .(1 / 3 )

 (2k / h)( R  r )  (k /  ) ln( 1 / 3 )  k / 

 (2k / h)( R  r )  (k /  ) 1  ln( 1 / 3 ) 
p2  (2k / h)( R  r )  (k /  )1  ln( 
3 ) ______________(7) , (0  r  rs )

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Total Forging Force :
rs R
F   p 2 .2r.dr   p1 .2r.dr
0 rs

rs R 
 2   p 2 .r.dr   p1 .r.dr 
 0 rs 

rs  rs
 
 R
 2   (2k / h)( R  r )r.dr   2   (k /  ) 1  ln( 3 ) r.dr   2   3ke( 2  / h )( R  r )

.r.dr 
 0   0  rs 

 2 (2k / h) ( Rr 2 / 2)  (r 3 / 3)  rs
0
 
 2 (k /  (r 2 / 2)  ln( 3 )( r 2 / 2)  2  3ke( 2  / h)( R  r ) .r.dr

 
 2 (2k / h)r 2 R / 2  r / 3  (kr 2 / 2 ) 1  ln( 3 )  rs
0
 
 2 3ke( 2  / h)( R  r ) .( h 2 / 4 2 )1  (2r / h)
R
rs

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Grain Flow Comparison

(a) casting, (b) machining, (c) forging

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Types of Forging

Smith forging
Drop forging
Press forging
Upset forging
Swaging
Roll forging

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Roll Forging

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Die Features

Fillet radius
Draft
Flash gutter
Shrinkage allowance (hot forging)

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Forging Defects

Unfilled sections – less metal, improper heating,

misplacement of metal
Scale pits – scale in die
Mismatched forging – misalignment of two halves of die
Barreling – low lubrication
Laps – thin web
Internal cracks – thick web

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Forging Defects

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

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