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Forging Metal

Forging is an ancient metalworking process where compressive forces are used to shape metal. Common forged products include bolts, rivets, gears, and connecting rods. There are two main forging methods: open-die forging uses flat dies and is the simplest process, while impression and closed-die forging uses shaped dies to form parts close to their final dimensions, requiring less subsequent machining. Forged parts have good strength and toughness due to favorable grain structure formation under compressive stress.

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Ginu Thomas
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62 views14 pages

Forging Metal

Forging is an ancient metalworking process where compressive forces are used to shape metal. Common forged products include bolts, rivets, gears, and connecting rods. There are two main forging methods: open-die forging uses flat dies and is the simplest process, while impression and closed-die forging uses shaped dies to form parts close to their final dimensions, requiring less subsequent machining. Forged parts have good strength and toughness due to favorable grain structure formation under compressive stress.

Uploaded by

Ginu Thomas
Copyright
© Attribution Non-Commercial (BY-NC)
We take content rights seriously. If you suspect this is your content, claim it here.
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Download as PPT, PDF, TXT or read online on Scribd
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Forging of Metals

Introduction

A metal is shaped by compressive forces Oldest metal working process 4000BC Can be performed with a hammer and anvil Typical forged products:

Bolts Rivets Connecting rods Gears

Lading-gear components for the C5A and C5B transport aircraft, made by forging.

Steps involved in forging a bevel gear with a shaft.

Outline of Forging and Related Operations

Grain Structure

Parts have good strength High toughness Forgings require additional heat treating

Fig : A part made by three different procedures, showing grain flow (a) casting (b) machining (c) forging

Open-Die Forging

Is the simplest forging process Sizes can very from very small parts to very large parts

Open-Die Forging

Upsetting or flat-die forging a solid workpiece is placed between flat dies and is compressed Barreling

caused by frictional forces at the die-workpiece interfaces Can be minimized if a lubricant is used Thermal effects caused by barreling can be minimized by using heated dies

Open-Die Forging

Forging force

Impression-Die & Closed-Die Forging

The workpiece acquires the shape of the die cavities while being forged between the two shaped dies

Impression-Die & Closed-Die Forging


The blank to be forged is prepared by:

Cutting from a bar stock Preformed blank Casting Preformed blank from prior forging

Impression-Die & Closed-Die Forging

Fullering & edging are used to distribute the material


Fullering material is distributed away from an area Edging material is gathered into an area

Blocking rough shaping of the part Impression dies give the part its final shape

Precision Forging

Used for economic reasons The part formed is close to the final dimensions Less machining is needed Higher capacity equipment is needed Aluminum and Magnesium alloys work well in the process

Coining

Closed-die forging process

Used for minting coins, medallions, & jewelry Lubricants can not be used in coining Can be used to improve surface finish

THE END

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