Proses Prod1-6

Materi 6
MK Proses Produksi 1
Masalah dan Cacat pada Rolling
• Problems:
– Roll deflection
– Spreading
• Defects:
– Wavy edges
– Cracks
– Alligatoring
– Residual stress
Forging
Deformation process dimana benda kerja dikompres
diantara dua dies (cetakan)
• Merupakan operasi metal forming yang tertua,
tercatat sejak tahun 5000 B C
• Components: engine crankshafts, connecting rods,
gears, aircraft structural components, jet engine
turbine parts
• In addition, basic metals industries use forging to
establish basic form of large components that are
subsequently machined to final shape and size
ISE 316 - Manufacturing
Processes Engineering
Forging grain flow
Klasifikasi Operasi Forging
• Cold vs. hot forging:
– Hot or warm forging – most common, due to the
significant deformation and the need to reduce
strength and increase ductility of work metal
– Cold forging - advantage is increased strength
that results from strain hardening
• Impact vs. press forging:
– Forge hammer - applies an impact load
– Forge press - applies gradual pressure
Types of Forging Dies
• Open‑die forging - work is compressed between
two flat dies, allowing metal to flow laterally
without constraint
• Impression‑die forging - die surfaces contain a
cavity or impression that is imparted to workpart,
thus constraining metal flow - flash is created
• Flashless forging - workpart is completely
constrained in die and no excess flash is
produced

Open-die Forging
• The simplest forging process.The workpiece is placed
between two flat dies and reduced in height by
compressing.
• Used for changing the microstructure from cast
structure to a wrought structure
• Forging force:
Yf = material flow stress
2 r  = friction coefficient
F  Y f r (1 
2
)
3h r = radius
h = height
Deformation operation reduces height

and increases diameter of work (similar
to compression test)
Stages in Open-Die Forging
(a) forge hot billet to max diameter
(b) “fuller: tool to mark step-locations
(c) forge right side
(d) reverse part, forge left side
(e) finish (dimension control)
[source:www.scotforge.com]
Open‑Die Forging with No Friction
If no friction occurs between work and die surfaces, then
homogeneous deformation occurs, so that radial flow is
uniform throughout workpart height and true strain is given
by:
ho
  ln
h
where ho= starting height; and h = height at some point during

compression
• At h = final value hf, true strain is maximum value
Figure 19.11 ‑ Homogeneous deformation of a cylindrical workpart under
ideal conditions in an open‑die forging operation:
(1) start of process with workpiece at its original length and diameter, (2)
partial compression, and (3) final size
Open-Die Forging with Friction
• Friction between work and die surfaces constrains lateral
flow of work, resulting in barreling effect
• In hot open-die forging, effect is even more pronounced
due to heat transfer at and near die surfaces, which cools
the metal and increases its resistance to deformation

Figure 19.12 ‑ Actual deformation of a cylindrical workpart in open‑die forging,
showing pronounced barreling:
(1) start of process, (2) partial deformation, and (3) final shape

Closed-die forging
• Benda kerja mendapatkan bentuk rongga
die, sewaktu ditempa diantara dua dies.
• Forging force:
F = k Yf A
where k = multiplying factor (table 14.1)
Yf = flow stress
A = projected area
Forging: Heat Loss
Metal near die surfaces are coolest, flow less
www.lft.uni-
erlangen.de
www.freedomalloysusa.com
Range of k values
Simple shapes, without

3-5
flash
Simple shapes, with

5-8
flash
Complex shapes, with

8 - 12
flash
Impression‑Die Forging
Kompressi benda kerja dengan cetakan yang
mempunyai bentuk berlawanan dengan bentuk part
yang diinginkan
• Flash is formed by metal that flows beyond die cavity
into small gap between die plates
• Flash must be later trimmed from part, but it serves
an important function during compression:
– As flash forms, friction resists continued metal flow into
gap, constraining material to fill die cavity
– In hot forging, metal flow is further restricted by cooling
against die plates
Impression‑Die Forging Practice
• Several forming steps often required, with separate die
cavities for each step
– Beginning steps redistribute metal for more uniform
deformation and desired metallurgical structure in subsequent
steps
– Final steps bring the part to its final geometry
– Impression-die forging is often performed manually by skilled
operator under adverse conditions

Impression-Die Forging
Forging die
Sequence in impression‑die forging: (1) just prior to initial contact with raw
workpiece, (2) partial compression, and (3) final die closure, causing flash to form in
gap between die plates.
Stages in Impression-die (Closed-Die) Forging
Impression‑Die Forging
Advantages and Limitations
• Advantages compared to machining from solid stock:
– Higher production rates
– Conservation of metal (less waste)
– Greater strength
– Favorable grain orientation in the metal
• Limitations:
– Not capable of close tolerances
– Machining often required to achieve accuracies and
features needed, such as holes, threads, and mating
surfaces that fit with other components
Flashless Forging
Compression of work in punch and die tooling

whose cavity does allow for flash
• Starting workpart volume must equal die cavity
volume within very close tolerance
• Process control more demanding than
impression‑die forging
• Best suited to part geometries that are simple
and symmetrical
• Often classified as a precision forging process
Figure 19.10 ‑ Three types of forging (c) flashless forging

Figure 19.18 ‑ Flashless forging:
(1) just before initial contact with workpiece,
(2) partial compression, and
(3) final punch and die closure
Forging Hammers (Drop Hammers)
• Apply an impact load against workpart - two types:
– Gravity drop hammers - impact energy from falling weight of a
heavy ram
– Power drop hammers - accelerate the ram by pressurized air or
steam
• Disadvantage: impact energy transmitted through anvil
into floor of building
• Most commonly used for impression-die forging

Figure 19.20 ‑ Drop forging hammer, fed by conveyor and heating units
at the right of the scene
(photo courtesy of Chambersburg Engineering Company)

Figure 19.21 ‑ Diagram showing details of a drop hammer for
impression‑die forging


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Materi 6

ISE 316 - Manufacturing

Deformation operation reduces height

(a) forge hot billet to max diameter

(b) “fuller: tool to mark step-locations

(c) forge right side

(d) reverse part, forge left side

(e) finish (dimension control)

where ho= starting height; and h = height at some point during

ISE 316 - Manufacturing

ISE 316 - Manufacturing

Simple shapes, without

Simple shapes, with

Complex shapes, with

ISE 316 - Manufacturing

Compression of work in punch and die tooling

ISE 316 - Manufacturing

ISE 316 - Manufacturing

ISE 316 - Manufacturing

ISE 316 - Manufacturing

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