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.

1. MANUFACTURING
TECHNOLOGY – I
CRAFTED BY:
RAMESH KUMAR A
Assistant Professor
Sona College of Technology
Salem
07-02-2019 05:42 1

2. FORGING
07-02-2019 05:42 2

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
07-02-2019 05:42 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
07-02-2019 05:42 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
07-02-2019 05:42 6

7. CLOSED DIE FORGING
07-02-2019 05:42 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

8. CLOSED DIE FORGING
07-02-2019 05:42 8

9. DROP FORGING
07-02-2019 05:42 9
 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

10. DROP FORGING
07-02-2019 05:42 10

11. HAMMER FORGING
07-02-2019 05:42 11
 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 05:42 12
 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 05:42 13
 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

14. MACHINE FORGING
07-02-2019 05:42 14

15. FORGING TOOLS
07-02-2019 05:42 15
 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 05:42 16
 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 05:42 17
 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 05:42 18
 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