MANUFACTURING PROCESS

EAT 227

WEEK 8
HOT WORKING AND COLD WORKING

PowerPoint Slides
by Turnad Lenggo Ginta

Last Updated:13 July 2017 LMS SEGi College 1

 Forging of Metals
Forged Components

Figure (a) Schematic illustration of the steps involved in forging a knife. (b) Landing-
gear components for the C5A and C5B transport aircraft, made by forging. (c) General
view of a 445 MN (50,000 ton) hydraulic press.
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 Forging
Definition
Forging is a Bulk Deformation Process in which the work is compressed
between two dies. According to the degree to which the flow of the metal is
constrained by the dies there are three types of forging:\

Open-die forging
Impression-die forging
Flashless forging

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 Open-die forging
Known as upsetting, it involves compression of a work between two flat dies, or
platens.

Sequence in open-die forging illustrating the

unrestrained flow of material. Note the barrel
Open-die forging of a multi diameter shaft
shape that forms due to friction and
inhomogeneous deformation in the work

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 Impression-die forging
In impression-die forging, some of the material flows radially outward to form a flash:

Estimation of the maximum force F

can be approximately done by
F = KfYfA
where Kf is the shape factor
ranging from 6 to 10, bigger for
more complex shapes, Yf is the
yield strength of the material at Stages (from bottom to top) in the
work temperature, A is the formation of a crankshaft by hot
projected area of the part, including impression-die forging
flash. July 2017
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 Impression-Die Forging

Figure (a) through (c) Stages in impression-die forging of a solid round billet. Note
the formation of flash, which is excess metal that is subsequently trimmed off (d)
Standard terminology for various features of a forging die.
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 Flashless forging
The work material is completely surrounded by the die cavity during compression
and no flash is formed:

Flashless forging: (1) just before initial contact with the workpiece, (2) partial compression,
and (3) final push and die closure. Symbol v indicates motion, and F - applied force.

Most important requirement in flashless forging is that the work volume must equal
the space in the die cavity to a very close tolerance.

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 Closed-Die Forging Versus Flashless
Forging

Figure 14.9 Comparison of closed-die forging with flash (left side of each illustration) and
precision or flashless forging (right side) of a round billet. Source After H. Takemasu, V.
Vazquez, B. Painter, and T. Altan.

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 Microstructure as a Function of
Manufacturing Method

Figure (a) Casting, (b) Machining, and (c) forging.

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 Upsetting with Barreling
2r
Forging force, F Y f r 2 1
3h

Figure (a) Solid cylindrical billet upset between two flat dies. (b)
Uniform deformation of the billet without friction. (c) Deformation with
friction. Note the barreling of the billet caused by friction forces at the
billet-die interfaces.

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 Die Inserts

Figure Die inserts used in forging

an automotive axle housing.

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 Forging a Rod, Fullering, and Edging

Figure (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 properly distribute the material when preshaping the blank for forging.

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 The Coining
Process

(b)

Figure (a) Schematic illustration of the coining process. The earliest coins were
made by open-die forging and lacked precision and sharp details. (b) An example of
a modern coining operation, showing the workpiece and tooling.

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 Heading

Figure (a) Heading operation to form heads on fasteners, such as nails and rivets.
(b) Sequence of operations to produce a typical bolt head by heading.

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 Swaging with and without a Mandrel

Figure (a) Swaging of tubes without a mandrel; note the increase in wall
thickness in the die gap. (b) Swaging with a mandrel; note that the final
wall thickness of the tube depends on the mandrel diameter. (c) Examples
of cross-sections of tubes produced by swaging on shaped mandrels.
Rifling (internal spiral grooves) in small gun barrels can be made by this
process.
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 Defects in Forged Parts

Figure Examples of defects in forged parts. (a) Laps formed by web buckling during
forging; web thickness should be increased to avoid this problem. (b) Internal
defects caused by an oversized billet. Die cavities are filled prematurely, and the
material at the center flows past the filled regions as the die closes.
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Principles of
Various
Forging
Machines

Figure Schematic illustration of the principles of various forging machines. (a)

Mechanical press with an eccentric drive; the eccentric shaft can be replaced by a
crankshaft to give the up-and-down motion to the ram. (b) Knuckle-joint press. (c)
Screw press. (d) Hydraulic press.

Speed Ranges of
Forging Equipment
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 Extrusion and Drawing of Metals

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 Extrusion
Definition
Extrusion is a Bulk Deformation Process in which the work is forced to flow through
a die opening to produce a desired cross-sectional shape.

Figure Extrusions and examples of products

made by sectioning off extrusions. Source:
Courtesy of Kaiser Aluminum

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 Extrusion is performed in different ways
therefore different classifications are available:

Direct and indirect extrusion

Hot and cold extrusion
Continuous and discrete extrusion

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 Direct-Extrusion

Figure Schematic illustration of the direct-extrusion process.

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 In-direct-Extrusion

In indirect extrusion backward,

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(inverse extrusion) the material
flows in the direction opposite to
the motion of the ram to produce
a solid (top) or a hollow cross
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section (bottom).
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 Force and power analysis in extrusion

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 Types of Extrusion

Figure Types of extrusion: (a) indirect; (b) hydrostatic; (c) lateral;

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 Process Variables in Direct Extrusion

Figure Process variables in direct extrusion. The die angle, reduction in cross-section,
extrusion speed, billet temperature, and lubrication all affect the extrusion pressure.

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 Extrusion Force

A
Extrusion force, F Aol ln o
Af

Figure Extrusion constant k for various

metals at different temperatures.
Source: After P. Loewenstein

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 Types of Metal Flow in Extrusion with
Square Dies

Figure 15.6 Types of metal flow in extruding with square dies. (a) Flow pattern obtained at
low friction or in indirect extrusion. (b) Pattern obtained with high friction at the billet-
chamber interfaces. (c) Pattern obtained at high friction or with coiling of the outer regions of
the billet in the chamber. This type of pattern, observed in metals whose strength increases
rapidly with decreasing temperature, leads to a defect known as pipe (or extrusion) defect.

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 Extrusion Temperature Ranges

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 Extrusion-Die Configurations

Figure Typical extrusion-die configurations: (a) die for nonferrous metals; (b) die for
ferrous metals; (c) die for a T-shaped extrusion made of hot-work die steel and used
with molten glass as a lubricant. Source: (c) Courtesy of LTV Steel Company.

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 Extrusion in Creation of Intricate Parts

Figure (a) An extruded 6063-T6 aluminum-ladder lock for aluminum extension ladders.
This part is 8 mm (5/16 in.) thick and is sawed from the extrusion (see Fig. 15.2). (b-d)
Components of various dies for extruding intricate hollow shapes. Source: (b-d) After K.
Laue and H. Stenger

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 Design of Exruded Cross-Sections

Figure Poor and good examples of cross-sections to be extruded. Note the

importance of eliminating sharp corners and of keeping section thicknesses uniform.
Source: J.G. Bralla (ed.); Handbook of Product Design for Manufacturing. New York:
McGraw-Hill Publishing Company, 1986. Used with permission.

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 Extrusion of Heat Sinks

Figure (a) Aluminum extrusion used as a heat sink for a printed circuit board. (b) Die and
resulting heat sink profiles. Source: Courtesy of Aluminum Extruders Council.

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 Cold Extrusion Examples

Figure Two examples of cold extrusion. Thin arrows indicate

the direction of metal flow during extrusion.

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 Cold-Extruded Spark Plug

Figure Production steps for a cold-

extruded spark plug. Source:
Courtesy of National Machinery
Figure A cross-section of the
Company.
metal part in Fig 15.12
showing the grain-flow pattern.
Source: Courtesy of National
Machinery Company.

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 Impact-Extrusion Process

Figure Schematic illustration of the impact-extrusion process. The extruded parts are
stripped by use of a stripper plate, because they tend to stick to the punch.

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 Impact Extrusion

Figure (a) Impact extrusion of a collapsible tube by the Hooker process. (b) and (c)
Two examples of products made by impact extrusion. These parts also may be made
by casting, forging, or machining. The choice of process depends on the materials
involved, part dimensions, and wall thickness, and the product properties desired.
Economic considerations also are important in final process selection.

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 Chevron Cracking

Figure 15.16 (a) Chevron cracking (central burst) in extruded round steel bars.
Unless the products are inspected, such internal defects may remain
undetected and later cause failure of the parts in service. This defect can also
develop in the drawing of rod, of wire, and of tubes. (b) Schematic illustration
of rigid and plastic zones in extrusion. The tendency toward chevron cracking
increases if the two plastic zones do not meet. Note that the plastic zone can
be made larger either by decreasing the die angle or by increasing the reduction
in cross-section (or both). Source: After B. Avitzur.

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 9-MN (1000-ton) Hydraulic-Extrusion
Press

Figure 15.17 General view of a 9-MN (1000-ton) hydraulic-extrusion press.

Source: Courtesy of Jones & Laughlin Steel Corporation.

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 Process Variables in Wire Drawing

Figure Process variables in wire drawing. The die angle, the reduction in cross-sectional
area per pass, the speed of drawing, the temperature, and the lubrication all affect the
drawing force, F.

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 Tube-Drawing Operations

Figure Examples of tube-drawing operations, with and without an internal mandrel.

Note that a variety of diameters and wall thicknesses can be produced from the
same initial tube stock (which has been made by other processes).

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 Drawing Dies

Figure Terminology of a typical Figure Tungsten-carbide die insert in

die used for drawing a round rod a steel casing. Diamond dies used
or wire. in drawing thin wire are encased in a
similar manner.

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 Extruded Channel on a Draw Bench

Figure Cold drawing of an extruded channel on a draw bench to reduce its

cross-section. Individual lengths of straight rods or of cross-sections are
drawn by this method. Source: Courtesy of The Babcock and Wilcox
Company, Tubular Products Division.

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 Multistage Wire-drawing Machine

Figure Two views of a multistage wire-drawing machine that typically is used in the
making of copper wire for electrical wiring. Source: After H. Auerswald

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