Manufacturing processes- metal forging

1. Metal Forging
Prof. K.N.Wakchaure
Dept. of Mechanical Engineering
SRES COLLEGE OF ENGINEERING,
KOPARGAON

3. • Metal forgings can be small parts, or weigh as much as
700,000 lbs.
• Products manufactured by forging in modern industry
include critical aircraft parts such as landing gear, shafts for
jet engines and turbines,
• structural components for transportation equipment such as
automobiles and railroads, crankshafts, levers, gears,
connecting rods, hand tools such as chisels, rivets, screws,
and bolts to name a few.
• The manufacture of forging die and the other high costs of
setting up an operation make the production of small
quantities of forged parts expensive on a price per unit basis.

4. Video

26. Heading Or Upset Forging
• Heading or upset forging is a process by which
stock, (typically cylindrical), is upset at its end in
order to increase the cross section of the material
in this area.
• This metal forging process may be hot, but is
often a cold working operation.
• Cold working will take advantage of the
strengthening of the material in the region
worked.

27. Heading Or Upset Forging

28. Metal Piercing
• Piercing is a metal forging technique that is often
performed as an auxiliary process in conjunction
with other forging processes, in the manufacture
of a part.
• It can be used to create a cavity or hole in the
work piece

29. Metal Sizing
• Sizing is a metal forging process that is used
mainly to finish work that has already been
manufactured.
• It is a cold forming process.
• Metal sizing uses a lot of force over a short
distance, producing very accurate dimensions in
the finishing of these parts.
• This manufacturing technique can also be used
to create work with excellent surface quality.

30. Metal Ball Forging
• The ability to manufacture metal spheres with very
accurate dimensions and surface quality is
important in modern industry.
• One of the main applications of these metal balls is
for use as ball bearings.
• Ball bearings are widely used in mechanical
systems involving the translation of motion.

31. Ring Forging
• Seamless metal rings of different sizes are
commonly manufactured in modern industry for
various applications, such as parts for machine
tools, rockets, turbines, pipes, and pressure
vessels.

32. Riveting
• Riveting is a forging process that may be used to
join parts together by way of a metal part called
a rivet.
• The rivet acts to join the parts through adjacent
surfaces.
• A straight metal piece is connected through the
parts.
• Then both ends are formed over the
connection, joining the parts securely.

33. Metal Coining
• Metal coining is a forging process by which very
fine and intricate details can be created on the
surface of a work piece.
• Coining may be used to control surface quality
and detail on parts.
• Metal coining is often a finishing process for
manufactured products.

34. Trimming
• Trimming is a manufacturing process that is
used as a finishing operation for forged parts,
in order to remove flash.

36. Analysis of Open Die Forging

37. • True strain
• Force Required
• Flow Stress
• If effect of frictional force is considered,
• Forging shape factor

38. Problems