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Lecture Notes - Forging Calculation

[1] Forging is the process of shaping metals by hammering or pressing them between dies or molds. It produces a net shape and improves material properties. [2] The forging load is calculated using the slab method, which analyzes the stress distribution across the workpiece using equilibrium equations and yield criteria. The forging pressure decreases from the outer edges towards the center. [3] Sample problems demonstrate calculating the forging pressure distribution and average pressure for different geometries, materials, and degrees of deformation using the flow stress, friction coefficient, and dimensions.

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727 views21 pages

Lecture Notes - Forging Calculation

[1] Forging is the process of shaping metals by hammering or pressing them between dies or molds. It produces a net shape and improves material properties. [2] The forging load is calculated using the slab method, which analyzes the stress distribution across the workpiece using equilibrium equations and yield criteria. The forging pressure decreases from the outer edges towards the center. [3] Sample problems demonstrate calculating the forging pressure distribution and average pressure for different geometries, materials, and degrees of deformation using the flow stress, friction coefficient, and dimensions.

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Fabiano, Jr. Barcenal
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Mechanical Working of Metals

Forging
Forging
“The act of
shaping metal by
hammering or
pressing”

Forging is done in
special molds
called "dies"
Calculation of Forging Load
P

UPSET FORGING
Ideal vs Actual

HOMOGENOUS NONHOMOGENOUS
DEFORMATION DEFORMATION
Nonhomogenous Deformation

BARRELING
Effect of Friction on Forging
Pressure

Pressure builds-up at
the center creating a
pressure hill!
Effect of Friction on Forging
Load

The build-up of
pressure also creates
a Friction Hill
-Forging Load Calculation-
The SLAB METHOD

b = tool bite

ASSUME PLANE STRAIN (WIDTH IS CONSTANT)


Analysis of Stresses using
Slab Method
Equilibrium of forces in the horizontal direction:

( x + d x )h + 2 y dx −  x h = 0
and

2 y
d x + dx = 0
h
Since both σx and σy are unknown, another equation must be
obtained using yield criteria; specifically, the distortion-energy
criterion for plane strain is used.

 x − y = 2 Y = Y
Hence d x = d y
3
Analysis of Stresses using
Slab Method
The two equations for the stresses
can now be solved:
d y 2
= − dx →  y = Ce−2 x / h
y h
The value of the constant, C, is found
using the boundary conditions. At x=a,
σx=0 and σy= Y`
2 a / h
C = Y e
The value of the constant, C, is found using the boundary
conditions. At x=a, σx=0 and σy= Y`. The pressure is then

 2  (a − x ) / h
p =y =Ye
Simplification of Forging
Pressure Equation

2  (a − x )/ h
p =  y = Y e
If x<1 then exp(x ) ~ (1 + x)

2  (a − x)
p =  y = Y '[1 + ]
h
Y’ = 1.155Y When  > 0.5 use  = 0.5
Sample Problems

A copper slab was upset to give a final


dimension of 60 x 20 x 10 mm (L x W x H). If
the yield stress of copper is 40 MPa and the
coefficient of friction is 0.15, determine the
Forging Pressure at the following points on
the billet: P

i. At the middle
ii. At the ends
iii.(1/3)a distance from the middle
Average Forging Pressure, Pavg
The average pressure can
be approximated from the
mean of the maximum and
the minimum pressure

 a 
pavg  Y 1 + 
 h 
The forging load, F, is

( )
F = pavg (2a )(width )
Reminders on P and Pavg
2  (a − x )/ h  a 
p =  y = Y e pavg  Y 1 + 
 h 
Condition Flow Condition 
Stress
Plane Y’ = 1.155Y < 0.5 
Strain Slipping Friction
Homogenous Y > 0.5 1/2
Deformation Sticking Friction
Slipping Friction Sticking Friction
Plane Strain W/b > 4 is found in cold is found in hot
when working working
Sample Problems
A block of lead 25x25x150 mm³ is pressed
between flat dies to a size 6.25x100x150 mm³. If
the uniaxial flow stress σ = 6.9 Mpa and µ = 0.25,
determine the pressure distribution over the 100 mm
dimension (at x = 0, 25 and 50 mm and the total
forging load in the sticky friction condition.
P
Sample Problems
If the billet is 2.0 m long, 0.9 m wide and 0.2
m thick, calculate and compare the loads
required at the commencement and the
completion of forging. Assume plane strain
conditions so that the width remains
constant throughout. The tool bite is 0.3 m
and the tensile yield stress of the steel is 50
MN/m² at the start of forging and 150 MN/m²
at completion.
Sample Problem

Determine the Forging Load required to


reduce the thickness of half of a steel billet
100x40x10 mm (LxWxH) by 40% (assume
plane strain). Assume that the yield stress
of steel is 240 MPa and  = 0.65.
F

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