Forging PPT Hks.

 Name – Hrushikesh Samantaray
 Regd.No. – 211207121022
 Branch – Mechanical
 Semester – 4th
TOPIC
Forging
Contents
 Introduction
Introduction
 Forging is a deformation process in which the

work is compressed between two dies, using
either impact or gradual pressure to form the
part.
 It is the oldest of the metal forming operations,
dating back to perhaps 5000 B.C.
Forging …cont’d
 Today, forging is an important industrial process used to

make a variety of high-strength components for
automotive, aerospace, and other applications.
 These components include engine crankshafts and
connecting rods, gears, aircraft structural components,
and jet engine turbine parts.
 In addition, steel and other basic metals industries use
forging to establish the basic form of large components
that are subsequently machined to final shape and
dimensions.
Cont…
Types of forging processes
 Forging is carried out in many different ways

1. Based on working temperature:
• Cold forging
• Warm forging
• Hot forging
2. Based on source of power
• forging hammer ,Applied Impact load
• forging press, Applied Gradual pressure
Types of forging processes…cont’d
3. Based on the degree to which

the flow of the work metal:
• Open-die forging,
• Impression-die forging,
and
• Flash less forging.
Types of forging processes…cont’d
Three types of
forging operation:
(a) open-die
forging, (b)
impression-die
forging, and (c)
flashless forging.
1. Open-die forging
 The work is compressed between two flat (or

almost flat) dies, thus allowing the metal to flow
without constraint in a lateral direction relative
to the die surfaces.
 The simplest case of open-die forging involves
compression of a work part of cylindrical cross
section between two flat dies, much in the
manner of a compression test.
Open-die forging…cont’d
 This forging operation, known as upsetting or

upset forging, reduces the height of the work and
increases its diameter.
Homogeneous deformation of a cylindrical work part

under ideal conditions in an open-die forging
operation: (1) start of process with work piece at its
original length and diameter, (2) partial compression,
and (3) final size
 Open-die forging practice

• Open-die hot forging is an important industrial
process.
• Shapes generated by open-die operations are
simple; examples include shafts, disks, and rings.
• In some applications, the dies have slightly
contoured surfaces that help to shape the work.
• Skill of the human operator is a factor in the
success of these operations.
2. Impression-die forging
 Impression-die forging, sometimes called closed-

die forging, is performed with dies that contain the
inverse of the desired shape of the part.
 The raw work piece is shown as a cylindrical part
similar to that used in the previous open-die
operation.
 As the die closes to its final position, flash is
formed by metal that flows beyond the die cavity
and into the small gap between the die plates.
Impression-die forging…cont’d
 Although this flash must be cut away from the

part in a subsequent trimming operation, it
actually serves an important function during
impression-die forging.
 As the flash begins to form in the die gap, friction
resists continued flow of metal into the gap, thus
constraining the bulk of the work material to
remain in the die cavity.
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.
 Several forming steps are often required in

impression die forging to transform the starting
blank into the desired final geometry.
 Separate cavities in the die are needed for each
step. The beginning steps are designed to
redistribute the metal in the work part to achieve a
uniform deformation and desired metallurgical
structure in the subsequent steps.
 The final steps bring the part to its final geometry.
1. Flashless forging
 The term flashless forging is appropriate to identify this

process.
Flashless forging:
(1) just before initial
contact with workpiece,
(2) partial compression,
and (3) final punch and
die closure. Symbols v
and F indicate motion
(v = velocity) and
applied force,
respectively.
Flashless forging …cont’d
 Flashless forging imposes requirements on process

control that are more demanding than impression-
die forging. Most important is that the work
volume must equal the space in the die cavity
within a very close tolerance.
 It is the best to part geometries that are usually
simple and symmetrical, and to work materials
such as aluminum and magnesium and their alloys.
 Flashless forging is often classified as a precision
forging process.
Flashless forging…cont’d
 Forces in flashless forging can be computed using the same

methods as for impression die forging.
 Coining is a special application of closed-die forging in
which fine details in the die are impressed into the top and
bottom surfaces of the work part.
 A common application of coining is, of course, in the
minting of coins as shown in Fig.
 Coining is also used to provide good surface finish and
dimensional accuracy on work parts made by other
operations.
Flashless forging …cont’d
 The term flashless forging is appropriate to identify this process.
Coining
operation: (1) start
of cycle, (2)
compression
stroke, and (3)
ejection of
finished part.
Advantages of Forging
Some common advantages of forging are given as under.
1. Forged parts possess high ductility and offers great resistance to
impact and fatigue loads.
2. Forging refines the structure of the metal.
3. It results in considerable saving in time, labor and material as
compared to the production of similar item by cutting from a solid
stock and then shaping it.
4. Forging distorts the previously created unidirectional fiber as
created by rolling and increases the strength by setting the direction
of grains.
5. Because of intense working, flaws are rarely found, so have good
reliability.
6. The forged parts can be easily welded
Disadvantages of Forging
Few dis-advantages of forging are given as under.

1. Rapid oxidation in forging of metal surface at high temperature
results in scaling which wears the dies.
2. The close tolerances in forging operations are difficult to maintain.
3. Forging is limited to simple shapes and has limitation for parts having
undercuts etc.
4. Some materials are not readily worked by forging.
5. The initial cost of forging dies and the cost of their maintenance is
high.
6. The metals gets cracked or distorted if worked below a specified
temperature limit.
Applications of Forging
 Almost all metals and alloys can be forged.

 The low and medium carbon steels are readily hot forged without
difficulty,
 but the high-carbon and alloy steels are more difficult to forge
and require greater care.
 Forging is generally carried out on carbon alloy steels, wrought
iron, copper-base alloys, aluminum alloys, and magnesium
alloys.
 Stainless steels, nickel based super-alloys, and titanium are
forged especially for aerospace uses
Cont…
 Producing of crank shaft of alloy steel is a good example which

is produced by forging.
 Forging processes are among the most important
manufacturing techniques utilized
 widely in manufacturing of small tools, rail-road equipment,
automobiles and trucks and components of aero plane
industries.
 These processes are also extensively used in the
manufacturing of the parts of tractors, shipbuilding, cycle
industries, railroad components, agricultural machinery etc.
Thank you

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 Name – Hrushikesh Samantaray

 Forging is a deformation process in which the

 Today, forging is an important industrial process used to

 Forging is carried out in many different ways

3. Based on the degree to which

 The work is compressed between two flat (or

 This forging operation, known as upsetting or

Homogeneous deformation of a cylindrical work part

 Open-die forging practice

 Impression-die forging, sometimes called closed-

 Although this flash must be cut away from the

Sequence in impression-die forging: (1) just prior to

 Several forming steps are often required in

 The term flashless forging is appropriate to identify this

 Flashless forging imposes requirements on process

 Forces in flashless forging can be computed using the same

 The term flashless forging is appropriate to identify this process.

Few dis-advantages of forging are given as under.

 Almost all metals and alloys can be forged.

 Producing of crank shaft of alloy steel is a good example which

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