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Forming Operations

FORGING
COURESE-
Smith forging, Drop forging, press forging &
Machine forging, Description of Presses and
hammers, forging defects. Forging die design.
What is Forging?
Grain Structure Comparison
Parts have good strength
High toughness
Forgings require additional heat treating to improve its
mechanical properties
Fig : A part made by three different procedures, showing grain flow (a) casting
(b) machining (c) forging
Why Forging is Necessary ?
Typical Forging Operations
a,b - To shape the ends of the bars to
gather metals.

C- Fullering is used to reduce the
cross sectional area of a portion of
the stock.

D- the reduction in cross section of
the work with concurrent increase in
length is called drawing.

e. If the drawing-down operation is
carried out with a concave dies so as
to produce a bar of smaller diameter
is called swaging

Is the simplest forging process
Sizes can very from very small parts to very large parts
Open-Die Forging
Open-Die Forging
Upsetting or flat-die forging a solid work piece is
placed between flat dies and is compressed
Defects Associated with Open Die forging
Barreling
caused by frictional forces at the die-work piece interfaces
Can be minimized if a lubricant is used
Thermal effects caused by barreling can be minimized by using
heated dies
Impression-Die & Closed-Die Forging
The work piece acquires the shape of the die cavities while
being forged between the two shaped dies
Step-1 Step-2 Step-3
Impression-Die & Closed-Die Forging
The blank to be forged is prepared by:
Cutting from a bar stock
Preformed blank
Casting
Preformed blank from prior forging
Impression-Die & Closed-Die Forging
Steps Involved in Close Die Forging
Fullering & edging are used to distribute the material
Fullering material is distributed away from an area
Edging material is gathered into an area

Blocking rough shaping of the part

Impression dies give the part its final shape
Closed Die Forging
Purpose of Flash
1. It acts as a safety valve to store the
excess metal in the closed die
cavity.
2. The thin flash increases the flow
resistance to the system , so that the
pressure builds up to high to ensure
that metal fills all recesses of the
forging die cavity
Sectional view through closed die forging
Typical Curve of Forging load vs
Stroke for closed-die forging
Open Die Forging Closed Die Forging
Carried out between flat dies

For very simple shape

At low pressure

For large objects and small
quantity

Preprocessor for close die
forging
Carried out between two die halves

For complex shape

At high pressure

For mall objects and large quantity

Close dimensional tolerances
Typical Values of Velocity for different
Forging Equipments
Energy Restricted machines
Stroke-restricted machines
Load restricted machines
High Energy rate forging - HERF
Total Energy supplied to the blow in a
power drop hammer is given below
Classification of Forging and its Application
Hand forging :- Hand forging is emplayed only to shape
a small number of light forgings chiefly in repair shops.

Hammer forgings :- Usually used for small item forging.

Press forging :- Usually used for heavy item forging.

Machine forging :- For medium sized and large articles
requiring very heavy blows.

Drop forging :- For mass production of identical parts.

Forging Defects
Internal Cracks

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