FORGING

Forging
Deformation process in which work is
compressed between two dies
Oldest of the metal forming operations,
dating from about 5000 B C
Components: engine crankshafts,
connecting rods, gears, aircraft structural
components, jet engine turbine parts
Also, basic metals industries use forging
to establish basic form of large parts that
are subsequently machined to final
shape and size
MF F313 Metal Forming and
Machining By A K Digalwar
Classification of Forging Operations
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: increased strength that
results from strain hardening
Impact vs. press forging:
Forge hammer - applies an impact load
Forge press - applies gradual pressure
MF F313 Metal Forming and
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Classification of Forging Operations
MF F313 Metal Forming and
Machining By A K Digalwar
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.
Impression (Closed)Die Forging
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Advantages and Limitations
Advantages of impression-die
forging compared to machining
from solid stock:
Higher production rates
Less waste of metal
Greater strength
Favorable grain orientation in the metal
Limitations:
Not capable of close tolerances
Machining often required to achieve
accuracies and features needed
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Flashless Forging
Compression of work in punch and die tooling
whose cavity does not 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
MF F313 Metal Forming and
Machining By A K Digalwar
Flashless forging: (1) just before initial contact with workpiece, (2)
partial compression, and (3) final punch and die closure.
Flashless Forging
MF F313 Metal Forming and
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Types of Forging
Smith forging
Drop forging
Press forging
Upset forging
Swaging
Roll forging
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Forging Hammers (Drop
Hammers)
Apply 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
Commonly used for impression-die forging
MF F313 Metal Forming and
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Drop forging hammer, fed by conveyor and heating units at
the right of the scene (photo courtesy of Chambersburg
Engineering Company).
MF F313 Metal Forming and
Machining By A K Digalwar
Diagram showing details of a drop hammer for
impression-die forging.
Drop Hammer Details
MF F313 Metal Forming and
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Forging Presses
Apply gradual pressure to accomplish
compression operation
Types:
Mechanical press - converts rotation of drive motor
into linear motion of ram
Hydraulic press - hydraulic piston actuates ram
Screw press - screw mechanism drives ram
MF F313 Metal Forming and
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Upsetting and Heading
Forging process used to form heads on nails,
bolts, and similar hardware products
More parts produced by upsetting than any
other forging operation
Performed cold, warm, or hot on machines
called headers or formers
Wire or bar stock is fed into machine, end is
headed, then piece is cut to length
For bolts and screws, thread rolling is then
used to form threads
MF F313 Metal Forming and
Machining By A K Digalwar
An upset forging operation to form a head on a bolt or similar
hardware item The cycle consists of: (1) wire stock is fed to
the stop, (2) gripping dies close on the stock and the stop is
retracted, (3) punch moves forward, (4) bottoms to form the
head.
Upset Forging
MF F313 Metal Forming and
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MF F313 Metal Forming and
Machining By A K Digalwar
Examples of heading (upset forging) operations: (a) heading a nail
using open dies, (b) round head formed by punch, (c) and (d) two
common head styles for screws formed by die, (e) carriage bolt
head formed by punch and die.
Heading (Upset Forging)
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Swaging
Accomplished by rotating dies that hammer
a workpiece radially inward to taper it as
the piece is fed into the dies
Used to reduce diameter of tube or solid
rod stock
Mandrel sometimes required to control
shape and size of internal diameter of
tubular parts
MF F313 Metal Forming and
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Swaging process to reduce solid rod stock; the dies rotate as they
hammer the work In radial forging, the workpiece rotates while
the dies remain in a fixed orientation as they hammer the work.
Swaging
MF F313 Metal Forming and
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MF F313 Metal Forming and
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Trimming
Cutting operation to remove flash from
workpart in impression-die forging
Usually done while work is still hot, so a
separate trimming press is included at the
forging station
Trimming can also be done by alternative
methods, such as grinding or sawing
MF F313 Metal Forming and
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Trimming operation (shearing process) to remove the flash after
impression-die forging.
Trimming After Impression-Die Forging
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Roll Forging
MF F313 Metal Forming and
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Strip Forging
MF F313 Metal Forming and
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Assumption
forging force F attains its maximum value at
the end of the operation

variation of stress field along y-axis is
negligible
plane strain case
entire w/p is plastic in state during the process
constant is
MF F313 Metal Forming and
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Let at any instant the thickness of the
element is h and width is 2l
Consider an element of width dx at a
distance x from origin.
Consider the equilibrium of the element in
xdirection.
MF F313 Metal Forming and
Machining By A K Digalwar
) 3 ........( .......... ) / 2 (
0 2
) 1 (
) 2 ....( ..........
2
,
2 / ) (
[
) 1 ......( .......... 0 2
1 2
dx h dp
dx dp h
in puting
d dp
k p
criteria MISES VON apply
p
area plane of case a being it
stresses principal are p and x let now
dx d h
x
x
x
t
t
o
o
o o
o
t o
=
= +
=
= +
=

= +
MF F313 Metal Forming and
Machining By A K Digalwar
Now as we move along the x- axis from
origine, the friction stress are increasing
and when (say) it reaches a value equal to
shear yield stress and it remains constant
then after. In other words from
zone sticking a have we l x to x x
zone sticking non sliding a have we x x to x
s
s
,
/ , 0
= =
= =
MF F313 Metal Forming and
Machining By A K Digalwar
l x ke p
e k p or
h x k p
k c
k p x at equ from
c find to
c h x p dp
dx h p dp
becomes equ
p
x x to x ZONE SLIDING FOR
h x
h x
s
s s =
=
=
=
= = =
+ =
=
=
= =
0 ) 4 ( .......... 2
2 /
/ 2 ) 2 / ln(
2 ln
2 ), 0 ( 0 ) 2 (
/ 2 /
) / 2 (
) 3 (
) 0 (
/ 2
1
/ 2
1
1
1

t
MF F313 Metal Forming and
Machining By A K Digalwar
) 6 ( ]......... / ) ( [ 2
] / [ 2
2 ), 4 ( sin
) / 2 (
) / 2 (
,
tan
) 5 .....( .......... ) / 2 (
, int .
] , [
/ 2
) 3 ( sin
/ 2
/ 2
2
/ 2
2
2
2
. 2
h x x e k p
h x e k c
ke p equ g u now
x h k p c
c x h k p
p p x x
tc cons find to
c x h k p
have we egrating and equ above in k puting
k p x havex we
hdx dp
equ g u again
ZONE STICKING FOR
s
h x
s
h xs
hx
s
s s
s s
s s
s s
s
s
+ =
=
=
=
+ =
= =
+ =
=
= = =
=

t
t
t
MF F313 Metal Forming and Machining By A K Digalwar
l x x h x k p
h x h k
h x h e k p
get we equ in x puting
h x
h x or
e
ke k p
weget equ in this puting
k ps k p
x dx FIND TO
s
h h
s
s
s
h x
h x
s
s
s
s
s
s s + =
+ =
+ =
=
=
=
= =
= = =
=
) 7 ....( }]........ / ) 2 / 1 ln( 1 { 2 / 1 [ 2
)}] 2 / 1 ln( 2 / { / 1 2 / 1 [ 2
)}] 2 / 1 ln( 2 / { / 1 [ 2
), 6 (
) 2 / 1 ln( 2 /
) 2 / 1 ln( / 2
2 / 1
2 /
), 4 (
/
,
2
) 2 / 1 ln( ) 2 / )( / 2 (
/ 2
] / 2 [

MF F313 Metal Forming and

Machining By A K Digalwar
] 2 1 [ 2
/
0
} } + =
l
xs
xs
dx p dx p f
length unit force forging total
MF F313 Metal Forming and
Machining By A K Digalwar
Problem: A strip of lead with initial
dimensions 24mm X 24 mmX 150 mm is
forged between two flat dies to a final size
of 6 mm X 96 mm X 150 mm. If the
coefficient of friction between the job and
the dies is 0.25. Determine the maximum
forging force. The average yield stress of
lead in tension is 7 N/mm2
MF F313 Metal Forming and
Machining By A K Digalwar
DISC FORGING
MF F313 Metal Forming and
Machining By A K Digalwar
Let in a typical open die forging of a disc
as shown in figure, thickness and force at
the end of the operation are h and F
respectively:
Consider an elemental disc subtending an
angle d at the centre, between radii r
and r + dr.
MF F313 Metal Forming and
Machining By A K Digalwar
Considering the radial equilibrium of strip,

For the cylindrical symmetry,
(Assumption)
Now neglecting the higher order term
( ) 0 . 2 2 / sin . 2 . . ) )( ( = + + dr rd d h dr h rd h d dr r d
r r r
u t u o u o u o o
u
r
o o
u
=
MF F313 Metal Forming and
Machining By A K Digalwar
) 1 ________( __________ __________ __________ 0 2 .
0 2 . . .
=
= +
dr h d
dr rd h rd h rd d h rd
r
r r r
t o
u t u o u o u o
) 2 ( __________ __________ __________ __________ 3
6 ) ( ) ( ) (
,
Pr , ,
2 2
1 3
2
3 2
2
2 1
k p
get We
k
eq in values these Putting Therefore
Stresses incipal are p and Let
r
n
r
= +
= + +
o
o o o o o o
o o
u
MF F313 Metal Forming and
Machining By A K Digalwar
) 3 ( __________ __________ __________ __________ 0 2
) 1 (
= +
=
dr hdp
eq in Put
dp d
or
n
r
t
o
zone sticking r r
zone sliding R r r
e i
s
s
_______ 0
_______
. .
place takes sliding which beyond radius the is r Let
s
s s
s s
MF F313 Metal Forming and
Machining By A K Digalwar
1
) / 2 ( ln
,
) / 2 ( /
0 2
) 3 (
:
C r h p
g Integratin
dr h p dp
pdr hdp
eq in Put
p
Zone Sliding For
n
+ =
=
= +
=

t
MF F313 Metal Forming and
Machining By A K Digalwar
| |
r h R h
sl
R h
R h
R h
n
r
e e k p or
e k r h p Hence
e k C or
e k C or
C R h k
k p
eq from Therefore
R r
C find To
) / 2 ( ) / 2 (
) / 2 (
) / 2 (
1
) / 2 (
1
1
1
. 3
3 ln ) / 2 ( ln ,
3
) 3 /(
) / 2 ( ) 3 ln(
3
) 2 (
, 0 ,

=
+ =
=
=
+ =
=
= =
R r r e k p
s
r R h
sl
s s =

) 4 _______( __________ __________ 3
) )( / 2 (
MF F313 Metal Forming and
Machining By A K Digalwar
) 5 ____( __________ __________ ) / 2 ( ,
) / 2 (
0 2
) 3 ( ,
, ,
:
2
C r h k p g Integratin
dr h k dp or
kdr hdp
eq in k Putting
p also k r r At
Zone Sticking For
n
s s
+ =
=
= +
=
= = =
t
t t
MF F313 Metal Forming and
Machining By A K Digalwar
) 6 ___( __________ __________ 3 ) )( / 2 (
3 ) / 2 ( ) / 2 (
), 5 (
) / 2 ( 3
), 4 (
) / 2 (
) / 2 (
), 5 (
,
:
) )( / 2 (
) )( / 2 (
2
) )( / 2 (
2
2
2
2
s
s
s
r R h
s
r R h
s
n
s
r R h
n
s
n
s s
s s
n
s s
e k r r h k p
e k r h k r h k p
get we eq in C Putting
r h k e k C
eq above in value the put and r r putting by eq From
r h k p C or
C r h k p
eq in Putting
p p r r At
C Find To

+ =
+ + =
+ =
=
+ =
+ =
= =

MF F313 Metal Forming and

Machining By A K Digalwar
) 6 ( ,
) 3 / 1 ln( ) 2 / (
) 3 / 1 ln( ) 2 / (
) 3 / 1 ln( ) )( / 2 (
3 / 1
3 /
) 4 (
/
,
:
) )( / 2 (
) )( / 2 (
n
s
s
s
s
r R h
r R h
n
s
s s
s
eq in value r Putting
h R r
h r R
r R h
e
e k k
eq in this Putting
k p or
p k r r At
r Find To
s
s

=
=
=
=
=
=
= = =

MF F313 Metal Forming and

Machining By A K Digalwar
| |
{ } | |
| |
| |
| | ) 0 ( , ) 7 ____( __________ ) 3 ln( 1 ) / ( ) )( / 2 (
) 3 / 1 ln( 1 ) / ( ) )( / 2 (
/ ) 3 / 1 ln( ) / ( ) )( / 2 (
) 3 / 1 .( 3 ) 3 / 1 ln( ) 2 / )( / 2 ( ) )( / 2 (
3 ) 3 / 1 ln( ) 2 / ( ) / 2 (
3 ) 3 / 1 ln( ) 2 / ( ) / 2 (
2
) 3 / 1 ln(
) 3 / 1 ln( ) 2 / ( ) / 2 (
2
s
h R R h
r r k r R h k p
k r R h k
k k r R h k
k h h k r R h k
e k r h R h k
e k r h R h k p
s s + + =
+ =
+ =
+ =
+ =
+ =
+

MF F313 Metal Forming and
Machining By A K Digalwar
(
(

+ =
+ =
} }
} }
dr r p dr r p
dr r p dr r p F
Force Forging Total
s
s
s
s
r
R
r
r
R
r
. . . . 2
. 2 . . 2 .
:
0
1 2
0
1 2
t
t t
{ }
| | | |
{ } { } | | { } | |
R
r
r R h
r
r R h
r
R
r
r R h
r r
s
s
s
s
s s
h r h ke kr r R r h k
dr r ke r r k r Rr h k
dr r ke dr r k dr r r R h k
) / 2 ( 1 ) 4 / .( 3 2 ) 3 ln( 1 ) 2 / ( 3 / 2 / ) / 2 ( 2
. . 3 2 ) 2 / )( 3 ln( ) 2 / ( / ( 2 ) 3 / ( ) 2 / ( ) / 2 ( 2
. . 3 2 . ) 3 ln( 1 ) / ( 2 . ) )( / 2 ( 2
2 2 ) )( / 2 (
0
2 2
) )( / 2 ( 2 2
0
3 2
) )( / 2 (
0 0
t t
t t t
t t t

+ + + =
+ + + =
(
(

+
(
(

+ +
(
(

}
} } }
MF F313 Metal Forming and
Machining By A K Digalwar
Grain Flow Comparison
(a) casting, (b) machining, (c) forging
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Die Features
Fillet radius
Draft
Flash gutter
Shrinkage allowance (hot forging)
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Forging Defects

Unfilled sections less metal, improper heating,
misplacement of metal
Scale pits scale in die
Mismatched forging misalignment of two
halves of die
Barreling low lubrication
Laps thin web
Internal cracks thick web
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Forging Defects
(a) Laps formed by web buckling during forging; web thickness should be increased
to avoid this problem.
(b) (b) Internal defects caused by oversized billet; die cavities are filled prematurely,
and the material at the center flows past the filled regions as the dies close.
MF F313 Metal Forming and
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