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Forging
This document discusses various manufacturing technologies related to forging. It describes forging as a metalworking process involving plastic deformation between dies to achieve a desired shape. Forging can be classified based on the process (open die or closed die) or equipment (drop, power hammer/press, hand, or machine forging). The document outlines the key characteristics and applications of these different forging methods. It also describes various forging tools and common forging operations like upsetting, drawing down, setting down, bending, punching, welding, and cutting.
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Forging
- 1. MANUFACTURING TECHNOLOGY – I CRAFTEDBY: RAMESH KUMAR A Assistant Professor Sona College of Technology Salem 07-02-2019 05:42 1
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- 3. FORGING 07-02-2019 05:42 3 Forging is perhaps oldest metal working process and was known even during prehistoric days when metallic tools were made by heating and hammering Forging is basically involves plastic deformation of material between two dies to achieve desired configuration Depending upon complexity of the part forging is carried out as open die forging and closed die forging
- 4. CLASSIFICATION OF FORGING 07-02-201905:42 4 On the basis of process: Open die Forging Closed die Forging On the basis of equipment: Drop Forging Power (Hammer & press) Forging Hand Forging Machine Forging Forging Process Open die Forging Hand Forging Power Forging Power Hammer Press Forging Closed die Forging Drop Forging Press Forging Machine Forging
- 5. OPEN DIE FORGING 07-02-201905:42 5 This process also known as smiths die forging or flat die forging The operation is carried out between two flat dies of very simple shape generally b/w the bottom surface of hammer & top surface of anvil The work piece reduces their height/ plastically deform by compressing it The process is used for mostly large objects or when the number of parts produced is small and to perform the work-piece for closed-die forging Tooling is simple, inexpensive and allows the production of a large variety of shapes
- 6. OPEN DIE FORGING 07-02-201905:42 6
- 7. CLOSED DIE FORGING 07-02-201905:42 7 This process is also called impression die forging In this metal is deformed under high pressure between two dies (called tooling) or in a closed cavity that contain a profile of the desired part Closed die forging are commonly use where mass production of identical and more complex shapes of greater accuracy are required The process provide precision forging with close dimensional tolerance Normally used for smaller components Closed dies are expensive
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- 9. DROP FORGING 07-02-2019 05:429 It is also called as stamping. It consists of special type of hammer known as drop hammer or drop stamp Perfectly made steel dies are used for forging The top part of the die is raised by mechanical links to a certain height The heated metal placed accurately in the bottom part of the die The top part of the die is then allowed to fall suddenly This gives a high blow and completes the work piece in a single operation
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- 11. HAMMER FORGING 07-02-2019 05:4211 Machine which is work by blow or impact to perform forging process is known as hammer forging Power hammer provides greater capacity, in which the ram is accelerated on the down stroke by steam or air pressure in addition to gravity Steam or air pressure is also used to raise the ram on the upstroke The upper die and ram are raised by friction rolls gripping the board After releasing the board, the ram falls under gravity to produce the blow energy The hammer can strike between 60-150 blows per minute depending on size and capacity STEAM DROP HAMMER
- 12. PRESS FORGING 07-02-2019 05:4212 Machine which is work on pressure to perform forging process is known as press forging The material gets uniformly deform throughout its entire depth Hydraulic presses are load-restricted machines in which hydraulic pressure moves a piston in a cylinder The full press load is available at any point during the full stroke of the ram Due to slow speed, contact time is longer at the die-metal interface, which causes problems such a heat lost from work-piece
- 13. MACHINE FORGING 07-02-2019 05:4213 In machine forging the material is only upset to get the desire shape The die consists of two parts, one called the stationary gripper die which is fixed to the machine frame and the other movable gripper die which moves along with the die slide of the up setter. The stock is held then between these two gripper dies It is used for making gears, blanks, shafts, excels, and similar parts
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- 15. FORGING TOOLS 07-02-2019 05:4215 TONGS : Tongs are used mainly for holding work of many section FLATTER : Flatter is used to give smoothness and accuracy to articles which have already been shaped by fullers and swages SWAGE : Swage is used to reduce/finish to round, square / hexagonal form It consists of two parts- The top part having a handle The bottom part having a square shank
- 16. FORGING TOOLS… 07-02-2019 05:4216 ANVIL : Anvil is used for supporting hot job while hammering is done for shaping it into various shapes. It is made of cast steel SWAGE BLOCK : It is used for holding hot bars during bending, support for punching holes in a job & various holes FULLERS : Fullers are used for necking down/to form depressions
- 17. FORGING OPERATIONS 07-02-2019 05:4217 UPSETTING : It is the operation by which the thickness/cross-sectional area of the work piece is increased at the expense of its length DRAWING DOWN : It is the operation by which the thickness/cross-sectional area of the work piece is reduced by increasing length SETTING DOWN : It is the local thinning operation performed by the set hammer
- 18. FORGING OPERATIONS… 07-02-2019 05:4218 BENDING : It is the operation by which the bend may be either curve/sharp corner can be produced PUNCHING : It is the process of making holes in the work piece using punch & hammer WELDING : It is the process of joining two surfaces of metal under pressure after they are heated to the welding temperature CUTTING : It is a form of chiselling where a long piece of stock is cut into several pieces of required length