Course Title: Industrial Metal Working Processes Sessional

Course No: MSE 4234

Pabitro Prosad Mondal

Lecturer
Dept. of Materials science & Engineering
Rajshahi University of Engineering & Technology

Dept. of Materials Science & Engineering Rajshahi University of Engineering & Technology
 Forging
Forging is perhaps oldest metal working process and was known even during prehistoric
days when metallic tools were made by heating and hammering.

Forging is the operation where the metal is heated and then a force is applied to
manipulate the metal in such a way that the required final shape is obtained.

It is a deformation process in which the work piece is compressed between two dies,
using either impact load or hydraulic load (or gradual load) to deform it.

Dept. of Materials Science & Engineering Rajshahi University of Engineering & Technology
 Why forging over other manufacturing?

❖Stronger Component: Forging provides better mechanical properties

,ductility and fatigue and impact resistance because this process refines
and direct the grain flow according to the shape of the piece.

❖Useable for a wide range of metals: Almost all metal like ferrous and non
ferrous ,any kind of steel .

❖Significant Savings: Provides cost savings. No metal loss, no need to

cutting grinding or finishing process.
❖Wide range of shapes and sizes:

Dept. of Materials Science & Engineering Rajshahi University of Engineering & Technology
 Forging Operations

Upsetting: It is the process of increasing the cross-

section at expense of the length of the work piece.

Drawing down: It is the reverse of upsetting

process. In this process length in increased and
the cross-sectional area is reduced.

Dept. of Materials Science & Engineering Rajshahi University of Engineering & Technology
 Forging Operations

Punching and drifting: Punching means an operation in which a punch is forced through
the work piece to produce a rough hole. Punching is usually followed by drifting i.e.,
forcing a drift in the punched hole through and through. This produces at better hole as
regards its size and finish.

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Dept. of Materials Science & Engineering Rajshahi University of Engineering & Technology
 Forging Operations

Cutting: This operation is done by means of hot

chisels and consists of removing extra,
metal from the job before finishing it.

Bending: Bending of bars, flats and other

such material is often done by a blacksmith.

Dept. of Materials Science & Engineering Rajshahi University of Engineering & Technology
 Forging Operations
Forge welding: Sometimes, it may become necessary to join two pieces of metal. Forge
welding of steel is quite common and consists of heating the two ends to be joined to white
heat (1050°C – 1150°C). Then the two ends of steel are brought together having previously
been given a slight convex shape to the surfaces under joining.

Dept. of Materials Science & Engineering Rajshahi University of Engineering & Technology
 Types of Forging(PMDS)

1. Smith Forging: This is the traditional forging operation done openly or open dies by
the village black smith ,modern shop floor by manual hammering or by power
hammering

2. Drop Forging: Done by closed impression dies by means of drop hammers.

3. Press Forging: Similar to drop forging where force is applied by hydraulic press

4. Machine Forging: Unlike the drop or press forging where the materials is drawn out
in machine forging.

Dept. of Materials Science & Engineering Rajshahi University of Engineering & Technology
 Drop Forging

This is the modern equivalent of smith forging where the limited force of the
blacksmith has been replaced by mechanical or steam hammer.

This process can be carried out by open forging where the hammer is replaced by a die
and the metal is manipulated manually on the anvil.

Dept. of Materials Science & Engineering Rajshahi University of Engineering & Technology
 Drop Forging

❖ Barreling is caused by frictional forces that oppose the outward flow of the
workpiece at the die interfaces
Minimized by using an effective lubricant
❖ Cogging or drawing out is an open-die forging operation where thickness of a bar is
reduced by successive forging steps at specific intervals
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 Die Drop Forging
Die drop forging is the type of closed die forging
where the tup and the anvil of the open die forging
is replaced by lower and upper dies. It is used for
mass production.

Fullering impression: Since drop forging involves only a

reduction in cross section with no upsetting, the very first step
to reduce the stock is fullering. The impression machined in
the die to achieve this is called fullering impression.
Edging impression: Also called as preform. This stage is used to gather the exact amount of
material required at each cross-section of the finished component. This is the most important
stage in drop forging.
Bending impression: This is required for those parts which have a bend shape. To improve the
grain flow, therefore a bending impression is incorporated after edging impression.

Dept. of Materials Science & Engineering Rajshahi University of Engineering & Technology
 Die Drop Forging
Blocking impression:
It is also called as semi finishing impression. Blocking is a
step before finishing. In forging, it is difficult for the
material to flow to deep pockets, sharp corners etc. Hence
before the actual shape is obtained, the material is allowed to
have one or more blocking impressions where it requires the
shape very near to final one. The blocking impression is
characterized by large corner radii and fillet but no flash.

Finishing impression:
This is the final impression where the actual shape required obtained. In order to ensure that the
metal completely fills the die cavity, a little extra metal is added to the stock. The extra metal
will form the flash and surround the forging in the parting plane.

Trimming:
In this stage the extra flash present around the forging is trimmed to get the forging in the usable form.

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 Upset Forging
Upset Forging increases the diameter by compressing its length.

It is specially done in high speed machine that are usually set up to work in the horizontal
plane to facilitate the quick exchange of work piece from one station to the next.

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Dept. of Materials Science & Engineering Rajshahi University of Engineering & Technology
 Upset Forging
There are three rules, which are based on geometric proportions:
Rule 1: The limit of length of unsupported stock that can be upset in one
blow without excessive buckling is not more than three times the diameter
of the bar

Rule 2: When the length of unsupported bar stock is more than three
times its diameter, the bar can be upset in one blow provided that the
diameter of the upset is not more than one and one-half times the
diameter of the stock
Rule 3: Where the length of unsupported bar stock is more than three times its diameter, and the
diameter of the upset is not more than one and one-half times the diameter of the stock, the bar can
be upset in one blow provided the amount of unsupported stock beyond the face of the die is not
greater than one and one-half times the diameter of the stock

Dept. of Materials Science & Engineering Rajshahi University of Engineering & Technology
 Press Forging
Press forging can be defined as the forming process of placing metal between two dies by
applying mechanical or hydraulic pressure.
Press forging is usually done on a forging press, a machine that exerts a gradual pressure
on a forging die. The metal shape is usually formed by a single punch stroke for each die
station.

Dept. of Materials Science & Engineering Rajshahi University of Engineering & Technology
 Press Forging
• Press forging is a process of applying progressive pressure to the die clamping the work
piece.
• This can be done as an open die or closed die forging process. In an open die press
forging process, the metal is surrounded only by one side of the die. For die pressing or
closed die forging, the metal work piece is enclosed in a mold and pressure is applied to
the mold.
• The work piece has plastic deformation and fills the mold cavity. In both the processes,
the forged part is pushed out of the die cavity by means of an ejector

Dept. of Materials Science & Engineering Rajshahi University of Engineering & Technology
 Press Forging

• Both, hydraulic presses and mechanical presses are employed for press forging
operation. The mechanical presses are used for light work while the hydraulic
presses are employed for heavy work.

• The mechanical press operates faster than the hydraulic presses but provides
less squeezing force.

• The contact of the workpiece in the die is measured in seconds whereas drop
forging and hammer forging is measured in milliseconds.

Dept. of Materials Science & Engineering Rajshahi University of Engineering & Technology
 Press Forging Vs Drop Forging
Comparison # Press Forging:
1. In press forging, the metal is shaped by means of a single, continuous stroke.
2. The pressure applied is slow, steady and continuous in a single squeezing action in
press forging.
3. The deformation obtained is uniform, simultaneous and deep penetrating at the center
of the metal part.
4. The impressions obtained in press forging are clean.
5. In press forging, the draft angles used are less.
6. The tong holds are not required.
7. The initial cost is higher than the drop forging.
8. The process is recommended when machine utilization is quite high.
9. The process forging is a faster process and has higher production rates.

Dept. of Materials Science & Engineering Rajshahi University of Engineering & Technology
 Press Forging Vs Drop Forging
Comparison # Drop Forging:
1. In drop forging, the metal is shaped by means of a series of blows.
2. The pressure applied is impact, and in multi-stroke in drop forging.
3. The deformation of metal is more at the surface layers than that of center of the metal
part.
4. The jarred impressions are obtained.
5. In drop forging, the draft angles used are more than that of press forging.
6. Tong holds are normally required for manipulating dies.
7. The initial cost is less comparatively.
8. The drop forging is suitable for almost all types of medium size forgings.
9. The drop forging is relatively slow process and has moderate production rates.

Dept. of Materials Science & Engineering Rajshahi University of Engineering & Technology
 Structure and Properties of Forging
The impact forge applies a stress period compared to a long period results in totally different
.structure.
Forging of a large piece of metal at high temperature will result in a very inhomogeneous
structure , the outside layers showing a typical Hot worked structure whilst the center is still
as cast.
Any attempt to achieve greater penetration by increasing impact load usually leads to
internal crack.

The second one from press forging is a

homogeneous product having high quality as
the process is slower and continuous

Fig: Microstructure developed after drop forging and

press forging
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 Grain Flow Lines

Fiver flow or Grain flow is a directional orientation of

metal grains and any inclusions that have been deformed by
forging. Individual grains are elongated in the direction of
the metal flow or plastic deformation.

Dept. of Materials Science & Engineering Rajshahi University of Engineering & Technology
 Grain Flow Lines

Dept. of Materials Science & Engineering Rajshahi University of Engineering & Technology
 Grain Flow Lines

Dept. of Materials Science & Engineering Rajshahi University of Engineering & Technology
 Effect of Friction in Forging
❖One effect of friction between W/P and the tool is to cause the vertical profile to become
barrel shaped, because the central portion deforms more than the upper and lower surface.
Deformation is inhomogeneous. This requires higher load and greater total energy
expenditure than for homogeneous deformation. This extra energy is called Redundant
work.

❖Second effect is to increase the deformation load due to friction, and to emphasize the
special role of friction in deformation processes. Press tool is loaded below its yield point ,
but the w/p exceeds the yield point that results elastic and plastic friction. This create a
large friction stress.
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 Forging defects
1.Incomplete forging penetration:

▪ Dendritic ingot structure at the interior of forging is not broken. Actual

forging takes place only at the surface.

▪ Cause: Use of light rapid hammer blows

▪ Remedy: Forging should be carried out slowly if not solved use forging
press instead of drop forging for full penetration.

Dept. of Materials Science & Engineering Rajshahi University of Engineering & Technology
 Forging defects
2. Surface Cracking
▪ Cause:
• Excessive working on the surface at too low temperature
• As a result of hot shortness
• Due to sticking friction.
• High sulfur in furnace leading to hot shortness

▪ Remedy: To increase the work temperature

stress relieving

Dept. of Materials Science & Engineering Rajshahi University of Engineering & Technology
 Forging defects
3.Cracking at the flash:This crack penetrates into the interior after flash is
trimmed off.

➢ Cause: Very thin flash

➢ Remedy:-Increasing flash thickness, relocating the flash to a less critical

region of the forging, hot trimming and stress relieving

Dept. of Materials Science & Engineering Rajshahi University of Engineering & Technology
 Forging defects
4. Cold shut (Fold):Two surfaces of metal fold against each other without welding
completely
• Cause: Sharp corner (less fillet), excessive chilling, high friction

• Remedy: increase fillet radius on the die

5.Scale pockets and Under fills: They are loose scale/ lubricant residue which
accumulate in deep recesses of the die.
• Cause: Incomplete descaling of the work
• Remedy: Proper descaling of work prior to forging
Dept. of Materials Science & Engineering Rajshahi University of Engineering & Technology
 Forging defects
6. Internal cracks

Cause: Secondary tensile stresses developed during forging

Remedy: Proper die design

7. Residual stresses in Forging:

Causes: Inhomogeneous deformation and improper cooling (quenching) of

forging.

Remedy: Slow cooling of the forging in a furnace or under ash cover over a
period of time.
Dept. of Materials Science & Engineering Rajshahi University of Engineering & Technology
 Forged Products in Today's Challenging Hi-Tech Applications

Dept. of Materials Science & Engineering Rajshahi University of Engineering & Technology
 Problem: A steel billet is to be forged. If the billet is 20 m long,0.9 m wide
and 0.2 m thick , calculate and compare the flash: This loads required at the
commencement and the completion of the forging. Assume plain strain
conditions so that width remains constant throughout,
The tool bite is 0.3 m and tensile yield strength is 500MN/m2 at the start of
the forging and 150 MN/m2 at completion.

Dept. of Materials Science & Engineering Rajshahi University of Engineering & Technology
 Problem: A cylindrical part is warm upset forged in a open die. The initial
diameter is 45 mm and initial height is 40 mm. The height after forging is 25
mm. The yield strength of the work materials is 285 MPA and its flow curve
is defined a strength coefficient of 600 MPA and a strain hardening exponent
of 0.12. Determine the force in the operations a) just as the yield point is
reached (yield at strain =0.002), b) at a height of 35 mm , c) at a height of
30 mm, d) at the height after forging.

Dept. of Materials Science & Engineering Rajshahi University of Engineering & Technology