FORGING OF METALS

Prepared By:DEVESH
AGRAWAL

FORGING OF METALS

Metal forging is one of the important aspects of

the metal forming process where deformation is
induced by localized compressive forces.

It involves application of the compressive forces

to a
work piece to deform it and to create the
desired geometric change to the material.
The equipment can be manual or power
hammers, presses, or special forging machines.
Metal undergoes triaxial compression during
forging .

WHY FORGING IS IMPORTANT

This process is generally used to produce
the discrete parts unlike rolling.
In rolling different structural components
are made on a continuous basis and then
after whatever length we desired we can
cut that much length using the shearing
machine.
Typical forged parts include rivets, bolts,
crane hooks, connecting rods, gears,
turbine shafts , hand tools and the variety
of the structural components used to
manufacture machinery.

FORGEABILITY
Fogeability

is generally defined as the

capability of a material to undergo
deformation without cracking.
The Greater the deformation prior to
cracking, greater will be the forgeability.
The metals are classified in order of their
forgeability.
The limit up to which the material can be
forged is cracking.
Al and mg can be forged easily than Ti.

TYPES OF FORGING PROCESSES

This

can be classified in several ways one is

HOT forging VS COLD forging

Most metal forging operations are carried out hot due
to
need to produce large amount of deformation in the
part and
the advantage of increment in ductility and reduced
strength of the work material.
It also eliminates the problem of strain hardened in
the material.
Forces that required will be comparatively less than
cold.

Although there are some disadvantages

some scale formation may takes place
control over the flow of the metal is not too much
in our hand. Dimensional control may not be that
good by this.
Another one is cold forging which having some
advantages like
Surface finish will be considerably better.
In cases where it is desirable to create a
favourable strain hardening of the part . cold die
forging may be employed.
produce greater surface finish and dimensional
accuracy than hot die forging.
Some specific metal forging processes are
always performed cold such as coining.

Disadvantages
Requiring higher forces
Process is not suitable for large scale
production.
Heavier and more powerful equipment is
required
There are three major classification of metal
forging process
open die forging
impression die forging
flashless forging

OPEN DIE FORGING

In

this the die is not enclosed in between the

flat punch and flat die we will bring our raw
material which has to be forged and then it
is held manually tang has been used and we
are applying the compressive forces.
This raw material can either be in cold or hot
state depending upon requirement.
Few points about this
Simplest forging process
Quite flexible but not suitable for large scale
production
Slow process
Quality depends on the skills of the operator.

UPSETTING
A

simple type of open die forging is called

upsetting. In an upsetting process the work
is placed between two flat die and its height
is decreased by compressive forces exerted
between the two die. These are of two types
Upsetting a flat die forging under ideal
condition

Upsetting in flat die forging under real

condition

COGGING
Cogging

is an open die forging process in which flat or

slightly contoured die are employed to compress a work piece,
reducing its thickness and increasing its length . In a cogging
operation, the forging is large relative to the size of the die.
Sometimes formed products such as m et al fences may be
produced directly from cogging .

FULLERING
Fullering

is used as an earlier step to help in

distribution of the material of the work In preparation
for further forging operation. Fullers are used for this.
eg.-forging of connecting rod for an internalcombustion engine.

EDGING
Edging

is also an open die forging process often

used in manufacturing practice, to prepare a work
for sequential metal forging processes. In edging ,
open di e with concave surfaces plastically deform
fullering both are used to redistribute bulk quantities
of the metal forging's material .

FORGING FORCE
The

forging force in case of open die

forging to be applied on a solid
cylindrical component can be
determined from following relation

IMPRESSION DIE FORGING

It is not like a open flat punch type
arrangement in this we use shaped
dies to control the flow of the metal.

The shape we want to make has been

exactly replicated in the form of the die.
the heated metal is positioned in the lower
cavity and one or more blows are struck by
the upper die this makes metal to flow and
fill the die cavity completely.
The excess of the metal is squeezed around
the periphery of the cavity to form flash. on
completion of the forging the flash is
trimmed out with the help of trimming dies.
In both open and impression forging the
shape may not be change from its initial to
final in one step it will done in no. of steps.

PRECISION FORGING
If

we want that the product which we are getting

near net shape .it should be according to the
desired shape & dimensional accuracy and the
finishing should be extremely good then we go to
precision forging no further machining is required.
it may produce some or no flash The number of
manufacturing operations is reduced as well as
the material wasted.
The disadvantages of these advanced forging
methods are that special machinery and die are
needed, also more careful control of the
manufacturing process i s required.
Its most basic type is flashless forging

FLASHLESS FORGING
Flashless

forging is a type of precision

forging process in which the entire
volume of the work metal is contained
with in the die and no material is
allowed to escape during the operation.
Since no material can leave the mold as
the part is forged, no flash is formed.

DEFECTS IN FORGING
Defects

of metal forged product

include exterior cracking, interior
cracking, laps, cold shuts, warping
of the part, improperly formed
sections and dead zones.

Cracking

both interior and exterior is

caused by excessive stress, or improper
stress distribution as the part is being
formed. high thermal gradient can
cause the cracks in the forged parts.

of a forged part can

happen when thinner sections

Warping

Cold shuts occur when metal flows of

different temperatures meet, they do not
combine smoothly, a boundary layer, (cold
shut ),forms at their intersection. It indicates
that there is is problem with the metal flow in
the mold as the part is being formed.
Laps in a metal forging are caused by a
buckling of the part , laps can be a result
of too little material in the work piece.
Improperly formed sections and dead zones
can be a result of too little metal in the work
piece. flawed forging die design resulting in
incorrect material distribu tion during the
process.

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