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Forging Online Education through FIRE (FORGE) is a three-year European Union funded project starting in October 2013 with a budget of 1.7 million Euros. The project brings together the FIRE (Future Internet Research and Experimentation) and online education communities. It aims to develop new online learning processes using FIRE facilities and eLearning technologies, introduce FIRE tools and concepts like experiment-driven research to higher education, and make FIRE platforms more accessible and usable for learning through guidance.
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DOCUMENTATION
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How to reduce hot forging costs through innovative techniques?
This presentation gives successful industrial case studies of cost reduction in hot forging by the use of:
1. Anti-scale protective coatings to prevent rejections due to scaling, reduce or eliminate shot blasting, reduce decarburization in heat treatment, hot rolling and hot forging.
2. Environment friendly die lubricants that eliminate pollution and increase die life.
3. Zero maintenance die lubricant spraying systems that ensure maximum uptime and no unplanned downtime during hot forging.
Warm Forging
Warm Group Companies provides gear blanking and shafts from 100cc to 1200cc. It has been supplying gear blanks for premium bikes for six years, with 25% of sales coming from BMW and BRP Rotex. Warm Group has various forging, machining, foundry, and other facilities to produce automotive and motorcycle components. It supplies precision forged parts for BMW, Harley Davidson, and the Indian market.
Flashless Forging
Flashless forging is a closed die forging process where metal is deformed in a die cavity with little to no excess flash. It is conducted at an elevated temperature between cold and hot forging. The preheated workpiece is compressed in the die until deformation occurs, producing a near-net or net-shaped part. Flashless forging requires tight process control of work volume and die cavity size to ensure proper filling. It is well-suited for producing simple, symmetrical parts and precision forgings from materials like aluminum.
Cost calculation of cnc machining operation
This document discusses the importance of calculating machine costs for CNC machining operations. It outlines the key fixed and variable costs to consider, including interest, depreciation, taxes, insurance, repairs, maintenance and energy. It recommends using methods like straight-line, diminishing balance or geometrically adjusted diminishing balance depreciation to accurately reflect the asset value over its lifetime. The conclusion emphasizes that operation costs depend mainly on machine run hours, workpiece complexity and raw material costs. Planning is important to set competitive prices and payments for the business.
Forging processes
Smith forging, also called flat die or open die forging, uses simple flat-faced dies and stock tooling to produce workpieces with less accuracy than impression or closed die forging. Impression die forging uses cavities in specially prepared dies to produce forged shapes in large quantities through drop, press, or machine forging. Closed die forging places a heated workpiece on a lower die while an upper die forces the metal to fill die contours. Hand forging shapes small forgings through hammering heated metal on anvils while power hammers and presses are used to forge larger parts through blows or squeezing.
Forging Process. [Workshop Practices]
Forging is an ancient metalworking process where a metal is compressed under force into a desired shape. It can be done using a hammer and anvil and produces parts with good strength and toughness. There are different types of forging processes, including open-die forging using flat dies, impression-die forging where the workpiece takes the shape of shaped die cavities, and coining where parts are precisely forged without lubricants between dies. Forged parts often require additional heat treating for optimal properties.
What is forging
1. Precision forging is a metal shaping process that uses plastic deformation to form parts close to their final dimensions, requiring little to no subsequent machining.
2. It involves refining traditional forging techniques like preheating, descaling, lubrication, and temperature control to achieve close tolerances and surface finishes.
3. Common applications include aircraft, power generation, and automotive components that have high dimensional and quality standards like connecting rods.
PPT ON FORGING
This document discusses various types of forging processes including hot forging, press forging, swaging, and cold forging. It describes how each process uses compressive forces and dies to shape metal at different temperatures. Examples of specific forging techniques are provided like hammer forging, drop forging, and upset forging. The document also outlines common forging tools, defects that may occur, and applications in small tools and automotive manufacturing.
Forging
Forging processes involve shaping metals by applying compressive forces. There are four main types: hammer/drop forging uses gravity impacts, press forging uses hydraulic or mechanical presses, and open-die and closed-die forging differ in whether dies fully contain the metal. Forging increases strength by working the metal and altering its microstructure. Proper die and process design are needed to control metal flow, fill dies completely, and minimize flash and defects. Die materials must withstand thermal and mechanical stresses, while coatings can extend die life.
forging processes
1) Properties of the billet material and how it deforms under different conditions of strain, strain rate, and temperature
2) Geometry and properties of the forging tools and die interface
3) Conditions within the deformation zone such as metal flow, stresses, and temperatures during forming
APQP
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Cost estimation is a critical task due to the small margins between production cost and selling price in a competitive market. For machining companies, this process is complex because of the high amount of variation occurring. An intelligent software system provides accurate cost estimation based on 3D CAD models.
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- 1. Forging Online Education through FIRE www.ict-forge.eu This project has received funding from the European Union's Seventh Framework Programme for research, technological development and demonstration under grant agreement no. 610889 PROJECT DATA Start Date: 01/10/2013; Duration: 36M EU Funding: 1,7M€ CONSORTIUM CONTACT John Domingue (The Open University) info@ict-forge.eu
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