Metallurgy
FORGING
Pr. ELHACHMI ESSADIQI UIR
4th of Automotive Engineering
2021/2022
FORGING
Forging - defined as metal working
process by which metals and
alloys are plastically deformed to
the desired shapes by the
application of compressive forces.
Classification:
➢ Open Die Forging
➢ Impression / closed die forging
(b)
(a)
(a) Schematic illustration of the steps involved
in forging a bevel gear with a shaft. (b)
Landing-gear components for the C5A and
C5B transport aircraft, made by forging.
4 Forging
Cold Forging
Requires greater forces and workpiece
materials must have sufficient ductility
at room temperature; good surface
finish and dimensional accuracy.
Hot Forging
Requires smaller forces, not as good
finish or dimensional accuracy; usually
require additional machining.
5
Forging
Forgeability
Capability of a material to undergo deformation without
cracking.
Forging is a discrete (individual) parts process
Forging is a near net shape process
Quality of forged parts
Surface finish/Dimensional control:
Better than casting (typically)
Stronger/tougher than cast/machined parts of same material
[source:www.scotforge.com]
Open Die Forging
Open die forging is performed between flat dies with no precut
profiles in the dies.
Larger parts over 200,000 lbs. and 80 feet in length can be
hammered or pressed into shape this way.
Open Die Forging
It is used
- Number of components to be forged is too small
- Size of the component is too large
Upper die
Billet
Lower die
Preliminary
Starting stock.
upsetting.
Progressive upsetting/
forging to disc dimension
Impression Die Forging
Impression die forging presses metal between two dies (called
tooling) that contain a precut profile of the desired part.
It produces closed dimensional tolerances
Parts from a few ounces to 60,000 lbs. can be made using this
process.
Some of the smaller parts are actually forged cold.
Impression-Die Forging
Stages in impression-die forging of a solid round billet. Note the formation of
flash, which is excess metal that is subsequently trimmed off (see Fig. 14.8).
Comparison of Forging With and
Without Flash
Comparison of
closed-die forging
to precision or
flashless forging of
a cylindrical billet.
Source: H.
Takemasu, V.
Vazquez, B.
Painter, and T.
Altan.
Impression Die Forging Process Operations
In impression die forging, two dies
are brought together and the workpiece
undergoes plastic deformation until its
enlarged sides touch the side walls of
the die. Then, a small amount of material
begins to flow outside the die impression
forming flash that is gradually thinned.
The flash cools rapidly and presents
increased resistance to deformation and
helps build up pressure inside the bulk of
the workpiece that aids material flow
into unfilled impressions.
16 Closed-Die Forging
flashless forging (flash does not form).
workpiece completely fills the die
cavity. Volume of material is precise.
Precision Forging: near-net-shape, net-
shape forging – (volume control –
gears, connecting rods)
Coining: pressures five to six times the
strength of material.
Engr 241-R1
Forging a Connecting Rod
(a) Stages in forging a
connecting rod for an
internal combustion
engine. Note the
amount of flash
required to ensure
proper filling of the
die cavities.
(b) Fullering, and
(c) edging operations to
distribute the material
when preshaping the
blank for forging.
Forging defects
Incomplete forging penetration (Dentritic structure
will not be broken at the interior surface)
Surface crack
High sulphur concentration in the furnace
atmosphere can produce HOT SHORTNESS in Steel &
Nickel
Crack at Flash
Cold shut
Loose Scale or lubricant may accumulate in deep
recess of the die
Incomplete descaling of workpiece
Internal cracks can develop during upsetting
Laps (Metal Fold)
Mismatch
Forging Operation
UPSETTING
HEADING
FULLERING
FLATTENING
EDGING
DRAWING OR NECKING
SETTING DOWN
SWAGING
PUNCHING
PIERCING
BENDING
20 Forging Machines
Presses
hydraulic
mechanical
screw
Hammers
gravity drop
power drop
Counterblow (two hammers)
high-energy-rate Machines (pneumatic)
Unit Cost in Forging
Figure Typical unit
cost (cost per
piece) in forging;
note how the
setup and the
tooling costs per
piece decrease
as the number of
pieces forged
increases, if all
pieces use the
same die.
Relative Unit Costs of a Small
Connecting Rod
Figure .
Relative unit costs of
a small connecting
rod made by various
forging and casting
processes. Note
that, for large
quantities, forging is
more economical.
Sand casting is the
more economical
process for fewer
than about 20,000
pieces.
