FLASH LESS FORGING PRSENTATION

1. Submitted by :
ASHISH GUPTA
44TH adc,
NIFFT,Ranchi

2. Whatis flashlessforging?
Flashless forging is a type of precision forging
process in which the entire volume of work metal
is contained within the die and no material is
allowed to escape during the operation.
Flashless forging is also called “true close die
forging”
The work material is completely surrounded by
the die cavity during compression and “no flash
is formed”.

3. Flashless forging is a type of impression die
forging in which the dies are designed to include
no flash areas.

4. Stepsinvolvedin flashlessforging:

5. IMPORTANT PARAMETERS FOR
FLASHLESS FORGING:
Billet volume
Preform or Blank
weight
Preform and tooling
temperatures and
thus the amount of
thermal expansions
Tool wear
Die alignment

6. FLASHLESS FORGING SEQUENCE

7. Forcein flashless Forging:

F  kYf A
Flow stress of
the materials at
the forging
temperature
Force required
for forging Projected area of
forging
Range of k value for equation:-
Simple shapes, without flash- 3-5

8. Comparisonof closedieforgingandflashlessforging:
Figure : Comparison of closed-die forging with flash (left side of each illustration)
and precision or flashless forging (right side) of a round billet.

9. Advantagesof flashlessforging:
The main advantage of flashless forging over conventional
die forging is its lower (by as much as 60%) material
consumption.
No trimming is required
Yield is improved
Machining cost and time is reduced
Heating energy saving from this process is approximately
20-30% less as compare to conventional hot forging
Better control on grain flow so strength will be higher
Lower capacity equipment can be used in flashless forging
because 25% of the total load is required in flash region in
conventional hot forging
Dimensional accuracy
Better surface finish

10. Disadvantagesof flashlessforging:
 Higher tooling cost due to complex die shape.
 Very careful calculation and cutting of stock material is required
 Best suited to part geometries that are simple and symmetrical.
 Complex shape is difficult to produce.
 Less tool life i.e. die and punch life.
 Better lubrication system is required.

11. Applicationofflashlessforging:
 In the past, flashless
forging processes have
been industrially
established for axis-
symmetric parts, e.g. gear
wheels and steering
pinions
 Connecting rod making
 Special piston for racing
cars
 Flashless forging is also
used in HAL for
manufacturing aerospace
and defence component.

12. APPLICATION
SPUR GEARS
AXLE SHAFT
BEVEL GEARS

13. Referances:
1. http://forgingmagazine.com/diesdie-materials/flashless-forging-two-cylinder-
crankshaft-secondry-form-elements
2. Forging Design Handbook. American Society for Metals 'Metals Park, Ohio.
1972.
3. Gr 6f , G., eermiik, J. : Close - Die Flashless Forging in Automotive Industry. In:
Journal for Technology of Plasticity. Novi Sad (Yugoslavia): Fac. of Technical
Sciences. Inst. for Prod. Eng., Vol. 26, No. 2, 2001, p. 1-10.
4. ASM Handbook- Vol 14- Forming And forging (2110s).
5. Victor Vazquez, Taylan Altan, ” Die design for flashless forging component part”
Journal of materials processing technology 98 (2000) 81-89.
6. A.M. Sabroff et al., Forging Materials and Practices, Reinhold, 1968.
7. K. Spies, “Preforming in Forging and Preparation of Reducer Rolling,” Ph.D.
dissertation, University of Hannover, 1959.
8. K. Vieregge, “Contribution to Flash Design in Closed-Die Forging,” Ph.D.
dissertation, Technical University of Hannover, 1969.
9. H.W. Haller, Handbook of Forging, Carl Hanser Verlag, 1971 (in German)
10. K. Lange and H. Meyer-Nolkemper, Closed-Die Forging, Springer-Verlag, 1977
(in German)
11.T. Altan, F.W. Boulger, J.R. Becker, N. Akgerman, and H.J. Henning, Forging
Equipment, Materials and Practices, Batelle Columbus, 1973.