Open Die Drop Hammer Forging

-Years ago, and in some forges today, the hammer was wielded by a skilled blacksmith. Historically,

many items including household implements and tools and decorative ornaments were made during
the hammer forging process. Today, hammer forging is responsible for producing components that
are required in engineering and many other industries where strong and reliable components are
required.
The hammer forging process involves a die that holds the workpiece in place whilst the hammer
shapes the malleable metal into the required shape. In hot forging the metal is heated so that it is
easy to manipulate whilst cold forging is carried out whilst the metal is at room temperature. The
materials used in hammer forging need to be suitable for the process and able to withstand high
temperatures and pressures.
There are various hammers used in the forging process today and the one used will depend on the
type of forging run that is being carried out. Hammer forging is most suitable for short runs and can
be a very cost effective and efficient method of manufacturing strong components for a range of
applications.
Parts Of Open Die Drop Hammer Forging

Anvil: This is the rigid base of the forging hammer. The anvil holds the lower
half of the forging die.
Die: The forging die decides the shape of the forging components. The
bottom half of the forging die is fixed with the anvil, and the top half of the die is
fixed with the ram.
Ram: The ram goes up and down and thus deforms the billet (or work piece)
to desired shape.

Board: It is the stem connected to the ram. Board goes up by friction wheels.
Friction Rolls: The friction rolls grip the board to drive it upward, once the
ram reached to the highest position friction rolls loosen its grip and the ram
freely fall and hit the billet. Thus the ram falls in quick succession to make a
forged component. Instead of friction rolls, the ram can be powered by a belt
and a motor as well.

Open Die Drop Hammer Forging Process

The diagram has been labeled as there is a flat punch, which has been
shown here, this is the flat punch, there is a head of hammer, this is the
head of the hammer
The arrow shows the movement, this will come down and go up, this will
moving this direction
Then there is a flat die, which is shown here, there is a press bed, this is
the work piece. We can see, we are giving shape to this work piece with
this head of the hammer then this work piece is held manually.
Open die means that the die is not enclosed, there is a flat punch and
there is flat die. In between the flat punch and the flat die, we will bring
the raw material, which has to be forced
This is held manually, we can see that tang has been used to hold the
work piece. And, we are applying the compressive forces. So, the basic
principle of forging operation is that the compressive forces are applied
onto the work piece, either manually or with the help of forging machines.

So, here we can see, we are able to change the shape of the product. This
raw material, it can either be in the cold state or it can be either in the hot
state.
In hot working, it has certain advantages and certain limitations, some
scale formation may take place the forces that are the required will be
comparatively less, the dimensional control may not be that good.
if we choose cold working operation, the force requirements will be
considerably higher, and the surface finish will be considerably better. So,
depending upon the final specifications of the product that we are making,
we have to make a decision that either to use a hot working operation or
to go for a cold working operation.
So, this is the basic principle of open die hammer forging.

Impression Die Drop Forging

-Impression-die forging is also called "closed-die forging". In impression-die
forging, the metal is placed in a die resembling a mold, which is attached to
an anvil. Usually, the hammer die is shaped as well. The hammer is then
dropped on the workpiece, causing the metal to flow and fill the die cavities.
Parts Of Impression Die Drop Forging

Pocess of Impression Die Drop Forging

-two dies are brought together and the workpiece

undergoes plastic deformation until its enlarged
sides touch the side walls of the die

a)

-Then, a small amount of material begins to flow

outside the die impression forming flash that is
gradually thinned.

b)

-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.

c)