This document summarizes upset forging and die design. Upset forging is a hot forging process that increases the diameter of a workpiece by compressing its length, typically starting with a wire or rod. It consists of multiple cavities in a die to allow for mass production. Proper die design is important to achieve defect-free forging. The document outlines the principle, construction, die design rules, advantages such as higher strength and productivity, limitations such as maximum diameter, and applications like nuts, bolts, and engine valves.

1. TOPIC
UPSET FORGING & DIE
DESIGN
BY – VIVEK CHANDRAVANSHI
MECHANICAL 5TH SEM

2. CONTENTS:
INTRODUCTION
PRINCIPLE
CONSTRUCTION & PROCESS
DIE DESIGN
ADVANTAGES
LIMITATIONS
APPLICATION

3. INTRODUCION
IT IS ALSO CALLED HOT HEADING PROCESS
IN UPSET FORGING DIAMETER OF WORKPIECE IS
INCREASED, BY COMPRESSING IT'S LENGTH.
GENERALLY THE INTIAL WORKPIECE IS TAKEN AS
WIRE OR ROD.
MAXIMAM DIAMETER OF WORKPIECE , WHICH CAN BE
UPSET IS LIMITED (MAX ABOUT 25 CM)
HERE PROCESS CONSIST MULTIPLE CAVITIES ,THEN
IT CAUSE OF MASS PROUDICTION .

4. PRINCIPLE
THIS FORGING OPERATION SELECTED WHEN CERTAIN
PARTS ARE REQUIRED WITH AN INCREASED DAIMETER AT
CENTER OR ONLY ONE END
UPSET FORGING ARE PRODUCED BY SQUEEGING
PRESSURE RATHER THAN BY AN IMPACT FORCE.
THIS PROCESS USUALLY DONE IN SPECIAL HIGH-SPEED
MACHINE CALLED CRANK PRESS.

5. CONSTRUCTION &
PROCESS:1. PROCESS CONSIST THREE MAIN COMPONENTS ,STATIONARY
DIE, MOVING DIE AND HEADING TOOL .
2. BAR STOCK PLACED IN POSITION.
3. AUTOMATIC STOCK GAUGE MOVES A SIDE , MOVING THE
STOCK IN CAVITIES OF THE DIES.
4. AFTER THE MOVING DIE AND HEADING TOOL BACK THEIR
ORIGINAL POSITIONS .

8. BOLTS
SCREWS
CRANK PRESSS ENGINE VALVES

9. DIE DESIGN:
TO ARRIVE THE SAFE AMOUNT OF UPSETTING IN A
GIVEN PASS, THE FOLLOWING THREE RULES ARE
TO BE SATISFIED TO ACHIEVE DEFECT FREE UPSET
FORGING:-
RULE 1: L ≤ 3D
IF NOT, THEN CAUSE BUCKLING.

10. RULE 2.
IF, L ≥ 3D THEN CONDTION IS REQUIRED
AND CONDTION IS UNSATISFIED ,
SO, FOR UPSETTING :
DIE CAVITY WIDTH ≤ 1.5D
FREE LENGTH < 0.5D

11. RULE 3. IF L > 3D & FREE LENGTH OUTSIDE
THE DIE UP TO 2.5D . THEN CONDITION IS
UNSATISFIED.
SO FOR UPSETTING,
DIE CAVITY WIDTH ≤ 1.5 D
BOTYOM SIZE =1.25D
HEADIND TOOL RECESS ≥ 2/3 (length of
working
Stock)

12. ADVANTAGES:
1.THE QUALITY OBTAINED OF PRODUCT ,GREATER
STREGTH.
2.HIGHER PRODUCTIVITY AND CHEAPER MAINTENACE.
3.UPSETTING PROCESS IS AUTOMATED.
4.SAVING IN MATERIAL AND NO OR LITTLE DRAFT IS
NEEDED .
5.FORGING IS ACCOMPAINED WITH LITTLE OR NO
FLASH.

13. LIMITATIONS:
1. NOT CONVENIENT TO FORGE HEAVIER JOBS DUE THE
MATERIAL HANDELLING DIFFICULTIES.
2. MAX. DIAMETER OF STOCK IS LIMITED 25 CM.
3. UNSYMMETRIC AND HEAVY JOBS ARE DIFFICULT TO
BE FORGED.
4.TOOLING COST MAY BE HIGH.

14. APPLICATION:
1. PRODUTION OF NUTS,
BOLTS,SCREWS,ROLLER AND BALL
BEARING BALLS,VALVE,GEAR BLANK ETC.

17. THANK YOU