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Metal Forming Metal Forming ‐ 3
Assoc Prof Zainal Abidin Ahmad FKM UTM
Lecture Outline 1. Int Intro roduc ductio tion n 2. Fo Forg rgin ing g operations 3. Clas Classifi sificat cation ion of of forging forging processes 4. Cl Clos osed ed and open die forging process 5. Eff ffect ect of of forging forging on microstructure 6. Ot Othe herr forging related processes – – Swaging – Roll forging
Introduction • Typical forged products are such as gears,
connecting rods, bolts
L anding-ge anding-gear ar components components for the C5A and C5B transport aircraft, aircraft, mad made e by forging forging 20-Aug-08
Steps involved in forging a bevel gear with a sh shaft. aft.
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2. Outline of of Forging Forging and Related Operations
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Forging Operations
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Forging Operations
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Forging Operations
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3. Classifications of of forging forging processes • By equipment – Forging hammer or drop hammer – Press forging
• By process – Open die forging –
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Forging machines
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Hammer and press forging processes • Forging hammers – Board hammer – Power hammer
• Forging presses – Mechanical press –
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Board hammer hammer – – for forging ging hammer
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Forging hammer or drop hammer
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of forging forging • Example of hammer or drop hammer supplied by the blow is equal to the potential energy due to the weight of of the the ram and the height of the fall 20-Aug-08
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Power hammer
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Hydraulic press forging • Using a hydraulic press or
metal, therefore, gives continuous forming at a slower rate. • Provides deeper penetration • Better properties (more • Equipment is expensive
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A general view of a 445 MN (50,000 ton) ton) hydraulic press. Source Source:: Wyman-Gordon Company.
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Mechanical press machine
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M echanical pre press wit with h an ecce eccentr ntric ic dri dr ive; the eccentr ntriic shaft can be re repl place aced by a cranksha crank shaft ft to give the up-and-down motion to the ram
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Principles of of Various Various Forging Machines (cont.)
Schematic illustration of the principles of various forging machines. (c) Knuckl K nuckle e-j -joint oint press. press. (d) Screw Screw pr pre ess. (e (e)) Gravity Gr avity drop hamm hammer. 20-Aug-08
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Typical values of of velocity velocity for various forging machines
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4. Closed and open die forging processes
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Open die forging • Open die forging is carried
out between flat dies or dies of of very very simple shapes • The process is used for
mostly large objects or when the number of of parts parts produced is small • Open die forging is often
used to pre‐form the workpiece for closed die forging 20-Aug-08
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Upsetting
Fi gure14.4 (a) Solid Figure Soli d cylindrical cylindrical bill bil letupset between two flat flat dies. (b) Uniform Uni form deformation of the billletwithout fri bil friction. ction. (c) Deformation with fri friction. ction. Note barreli rreling ng of thebil billet let caused by fri friction ction forces for cesat the bi billlet-di et-die e interf rface aces.
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Cogging Fi gure14.5 Two Figure views vi ews of a cogging rectangular bar. Blacksmiths use this process to reduce the thicknes thick ness of bars by hammeri ring ng the part on an anvil anvil.. Note the barreli rreling ng of the workpiece.
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Impression‐Die & Closed‐Die Forging Full ller erin in & ed in are used to distribute the • Fu material – Fullering – material is distributed away from an
area – Edging Edging – – material is gathered into an area
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oc ng – roug s ap ng o
e par
dies – – give the part its final shape • Impression dies
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Closed die forging (impression die forging) • The workpiece is deformed
between two die halves which carry ressio sions ns of the desired final the im res shape. • The workpiece is deformed under
high pressure in a closed cavity • Normally used for smaller
components • The process provide precision
forging with close dimensional tolerance • Closed dies are expensive 20-Aug-08
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5. Effect of of forging forging on microstructure
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Closed-die forging process Used for for mi mint ntiing coi coins ns,, medallions ons,, & jewe wellry
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Can be used to improve surface finish
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Heading/Upset Forging
(a) Headi ding ng operati ration, on, to form head ads s on fas faste tene ners rs such as nails and and rivets ri vets.. (b) Sequence of ope operati rations ons to produce a bolt head head by head adiing. 20-Aug-08
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Roll‐Forging
Two example Tw les s of the roll-fo ll-forrgin ing g operatio ion n, als lso o known as crossrolling.. Tapere rolling Tapered d lea leaf spri springs ngs and knives knives can be madeby this this process..
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Production of of Bearing Bearing Blanks
(a) Production of stee steel ba ballls by by the the ske skeww-rol rollling process. (b) Produ Pr oducti ction on of stee steel balls ball s by upse upsetting a cyl cyliindrical blan blank. k. Note the form ormation ation of flas ash. h. The ba ballls mad ade e by by these these process processe es are are subsequently ground and polished for use in ball bearings (see Sections 25.6 and 25.10). 20-Aug-08
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Swaging (a) Schem Schematic rotary-swaging process. (b) Forming internal profiles on a tubular workpiece workpi eceby swaging. (c) A dieclosing closi ng type type swaging machine, s ow ng orm orm ng o a steppedshaft. (d) Typ Ty pic ica al parts made by swaging.
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Swaging of of Tubes Tubes With and Without a Mandrel
(a) Swag Swaging of tubes without without amandrel; not theincre ncreas ase in wall wall thick thickne ness in thedie gap. gap. (b) Swag Swaging with a mandrel; notethat the final wall thick thickne ness of the tube depends on the mandrel di diam ameter. (c (c)) Exam Exampl ples es of cross-secti cross-sections ons of tubes produced producedby swaging swaging on shaped mandrels. Ri Riffling (spiral grooves) in in small gun barr rrels els can be madeby this thi s process. 20-Aug-08
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Classification of of Metals Metals in Decreasing Order of Forgeablilty of Forgeablilty TABL E 14.3 M etal or alloy Aluminum alloys Magne agnesium alloys all oys Copper alloys Carbon and low–all low– alloy oy steels Martensitic nsiti c stainles nless stee steels Austeniti nitic c stainles nless s steels Tita Titanium ium alloys lloys I ron-ba ron-base superall ralloys Cobalt-base superalloys Tan Tantalum lum alloys lloys Molybd olybde enumalloys alloys Nicke Ni ckell-base -base supe superalloys rall oys Tun Tungsten alloys lloys 20-Aug-08
A ppr oximate r ange of hot ° 400– 400–550 250– 250–350 600– 600–900 850–1150 850–1150 1100–1250 1100–1250 700– 700–950 1050–1180 1180–1250 1050–1350 1150–1350 1050–1200 1200–1300
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7. Defects in Forged Parts
Exampl ples esof defect ects s in forge forged parts. (a) Lab L abs form formed by web buckling buckli ng duri uring ng forgi orging; ng; web web thickne thickness should be increased to avoi void d this problem problem. (b) I nternal defec ects ts cause caused by oversized oversized bill bil let et;; di die e cavi viti tie es arefilled prem premat aturely, urely, and the materi rial al at the center fl flows past the filled regi regions ons as thedi dies es cl close ose.. 20-Aug-08
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Relative Unit Costs of of a a Small Connecting Rod Relative unit costs of a small connecting rod made by various forging and casting casting process processes. es. Note that, for large qua qu ant ntiities ties,, forg f orgiing is more economical cal.. Sand casting is the more economical process for , pieces.