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    Metal Forging: EDPT 604 Metal Forming Processes and Machines

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    ramy
    The document discusses metal forging processes and machines. It provides information on various forging techniques including open die forging, closed die forging, hot forging and cold forging. Open die forging uses an open mold and produces parts with flash that requires further trimming. Closed die forging demands high precision and can form parts without flash in a single operation. Forging improves the grain structure and mechanical properties of metals. Various examples of parts made through open die and closed die forging are also presented.

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    Metal Forging: EDPT 604 Metal Forming Processes and Machines

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    ramy
    124 views19 pages
    The document discusses metal forging processes and machines. It provides information on various forging techniques including open die forging, closed die forging, hot forging and cold forging. Open die forging uses an open mold and produces parts with flash that requires further trimming. Closed die forging demands high precision and can form parts without flash in a single operation. Forging improves the grain structure and mechanical properties of metals. Various examples of parts made through open die and closed die forging are also presented.

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    The document discusses metal forging processes and machines. It provides information on various forging techniques including open die forging, closed die forging, hot forging and cold forging. Open die forging uses an open mold and produces parts with flash that requires further trimming. Closed die forging demands high precision and can form parts without flash in a single operation. Forging improves the grain structure and mechanical properties of metals. Various examples of parts made through open die and closed die forging are also presented.

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    © All Rights Reserved
    Download as PDF, TXT or read online from Scribd
    Download as pdf or txt
    124 views19 pages

    Metal Forging: EDPT 604 Metal Forming Processes and Machines

    Uploaded by

    ramy
    The document discusses metal forging processes and machines. It provides information on various forging techniques including open die forging, closed die forging, hot forging and cold forging. Open die forging uses an open mold and produces parts with flash that requires further trimming. Closed die forging demands high precision and can form parts without flash in a single operation. Forging improves the grain structure and mechanical properties of metals. Various examples of parts made through open die and closed die forging are also presented.

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    © All Rights Reserved
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    of 19

    EDPT 604

    Metal Forming Processes and Machines

    Lecture 3
    Metal Forging

    Metal Forging Process

    Dr. Mohamed Harraz


    1

    Introduction Forging Process


    Forging is one of the oldest known metalworking processes. Traditionally,
    forging was performed by a smith using hammer and anvil, and though the use of
    water power in the production and working of iron dates to the 12th century, the
    hammer and anvil are not obsolete. Forging can be defined as a manufacturing
    process involving the shaping of metal using localized compressive forces.
    Forging is often classified according to the temperature at which it is performed:
    "cold", "warm", or "hot" forging. Forged parts can range in weight from less than
    a kilogram to 580 metric tons. Forged parts usually require further processing to
    achieve a finished part.
    In modern times, industrial forging is done either with presses or with hammers
    (see next slide) powered by compressed air, electricity, hydraulics or steam.
    These hammers may have reciprocating weights in the thousands of kilos.
    Smaller power hammers power, 230 kg or less reciprocating weight, and
    hydraulic presses are common in art smithies as well. Some steam hammers
    remain in use, but they became obsolete with the availability of the other, more
    convenient, power sources.
    Metal Forging Process

    Dr. Mohamed Harraz


    2

    Press Hammers

    Power press with a fixed


    barrier guard
    Power hammers are mechanical forging hammers that use a non-muscular
    power source to raise the hammer preparatory to striking, and accelerate it
    onto the work being hammered. Also called "Open Die Power Forging
    Hammers." They have been used by blacksmiths, metalworkers, and
    manufacturers since the late 1880s.
    Metal Forging Process

    Dr. Mohamed Harraz


    3

    Process and Advantages


    Forging is suitable for
    one-offs and low volume
    production as well as mass
    production runs.
    The drop forging process
    is particularly used in
    safety critic applications.
    At low volumes forging
    provides an alternative to
    machining, where as at
    high volumes it competes
    with casting.

    Drop Forging Process


    Metal Forging Process

    Dr. Mohamed Harraz


    4

    Quality of Drop Forging


    By its very nature, forging improves grain structure in the finished part. Metal
    billets go through plastic deformation as theyre forged and as a result the metal
    grains align in the direction of flow. This characteristic produces exceptional
    strength to weight properties and reduces stress concentrations that tend to occur
    in corners and fillets. Parts can be machined post-forging with no loss of quality,
    because there are no voids or porosity in the finished article. The tolerances
    range from 1 mm in small parts up to 5 mm in large parts, but vary according to
    requirements, because reducing tolerances increases costs. Forging is often
    combined with machining for improved accuracy. Cold coining or sizing in
    house can also close tolerances and reduce the need to machine some parts.
    This process is suitable for low volume production as well as one-offs. This is
    because it produces parts with superior strength to weight properties that cannot
    be manufactured in any other way. Small volumes can be machined from solid,
    but they will have to compensate for reduced strength brought about by random
    grain alignment. Undercuts are not possible in forging, however, it is possible to
    form undercuts and form joints with secondary forging operations
    Metal Forging Process

    Dr. Mohamed Harraz


    5

    Hot and Cold Working


    Hot working refers to processes where metals are plastically deformed above
    their recrystallization temperature. Being above the recrystallization temperature
    allows the material to recrystallize during deformation. This is important because
    recrystallization keeps the materials from strain hardening, which ultimately
    keeps the yield strength and hardness low and ductility high.
    Cold working also known as Work hardening or strain hardening, is the
    strengthening of a metal by plastic deformation. This strengthening occurs
    because of dislocation movements within the crystal structure of the material. Any
    material with a reasonably high melting point such as metals and alloys can be
    strengthened in this fashion.
    Some metals may be forged cold, but iron and steel are almost always hot forged
    . Hot forging prevents the work hardening that would result from cold forging,
    which would increase the difficulty of performing secondary machining
    operations on the piece. Also, while work hardening may be desirable in some
    circumstances, other methods of hardening the piece, such as heat treating, are
    generally more economical and more controllable.
    Metal Forging Process

    Dr. Mohamed Harraz


    6

    Effect of open die forging process


    on the crystal structure

    During this hot forging process, the cast, coarse grain structure is broken up and
    replaced by finer grains. Low-density areas, micro-shrinkage and gas porosity inherent
    in the cast metal are consolidated through the reduction of the ingot, achieving sound
    centers and structural integrity. Mechanical properties are therefore improved through
    the elimination of the cast structure, enhanced density, and improved homogeneity.
    Forging also provides means for aligning the grain flow to best obtain desired
    directional strengths. Secondary processing, such as heat treating, can also be used to
    further refine the part.
    Metal Forging Process

    Dr. Mohamed Harraz


    7

    Multistep forging process

    Scheme of the isothermal multistep forging process.


    Metal Forging Process

    Dr. Mohamed Harraz


    8

    Open and Closed die Forging

    Open-die forging

    Closed-die forging
    Metal Forging Process

    Dr. Mohamed Harraz


    9

    Flash vs. flashless closed die forging

    Trimming Flash
    by punching

    Metal Forging Process

    Dr. Mohamed Harraz


    10

    Die inserts closed die forging

    Die inserts used for forging an automotive axle

    Metal Forging Process

    Dr. Mohamed Harraz


    11

    Open Die Forging


    What is Open Die Forging?
    Open die forging is a forging process that forged the metal in an open mold. Open die
    forging products usually have a flash. The flash of forgings needs to be trimmed by press
    cutting machine. Both hot forging and cold forging can use open die forging process.
    Open die forging products require cutting, machining and polishing services.
    What materials were used for Open Die Forging?
    The materials of open die forging and closed die forging are basically the same. They
    could forge a variety of types of materials. The most common materials are carbon steel,
    alloy steel, stainless steel and copper alloy.
    Features of Open Die Forging
    1. Compared with drop forging, open-die forging products could make the shape in one
    time and have a good quality.
    2. Open die forging could improve the production efficiency for the parts which do not
    required high precision.
    3. Compared with the closed die forging, open die forging products require further
    machining to remove the flash.
    Metal Forging Process

    Dr. Mohamed Harraz


    12

    Examples of open die-forged parts

    Metal Forging Process

    Dr. Mohamed Harraz


    13

    Closed Die Forging


    What is Closed Die Forging?
    Closed die forging is a forging process that demands high precision and one-time forming
    shape. In some aspects, closed die forging is similar to precision forging. Closed-die
    forgings can be done without flash. This greatly improved working efficiency and reduced
    material costs. Closed die forging was also called impression die forging. Sometimes closed
    die forging used two or more molds to forge the metal. This will help the forging products
    directly to its final shape without flash.
    Materials used for Closed Die Forging
    The materials of closed die forging and open die forging are basically the same. The most
    common materials are carbon steel, alloy steel, stainless steel and copper alloy.
    Features of closed die forging
    1. The closed die forgings have high strength and precision surface treatment. Usually
    closed die forgings do not need machining process.
    2. Closed die forging need high precision molds. This is the most important part in closed
    die forging.
    3. For some forging products, closed die forging could save raw materials and reduce the
    products cost.
    Metal Forging Process

    Dr. Mohamed Harraz


    14

    Examples of closed die-forged parts

    Metal Forging Process

    Dr. Mohamed Harraz


    15

    Cogging (drawing out)


    Cogging operations are simple to set up
    and allow the use of separate top and
    bottom dies. A cogging operation can be
    set up in a single action with the
    movement and rotation of the billet
    entered in a simple table that also
    accounts for the cooling of the billet
    between blows and while resting on the
    bottom die.
    The billet can be held in place relative
    to either die or with a downward speed
    equal to half the speed of the top die to
    simulate any type of manipulator. The
    manipulator can be set up to allow for
    axial movement as the material is
    compressed.

    Linear motion and rotation


    in cogging operation

    Metal Forging Process

    Dr. Mohamed Harraz


    16

    Closed die forging

    Metal Forging Process

    Dr. Mohamed Harraz


    17

    Heading (upset forging)


    Open die

    Closed die

    Metal Forging Process

    Dr. Mohamed Harraz


    18

    End

    Metal Forging Process

    Dr. Mohamed Harraz


    19

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