5PE5662 Forg v13 PDF

4/10/2017
PE4652 – Teknologi Manufaktur

FORGING / TEMPA
Forging
• Forging is manufacturing process

where metal is pressed, pounded or
squeezed under great pressure into high
strength parts known as forgings.
TEKNIK DAN SISTEM PRODUKSI

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Advantages of Forging
 The forgings are consistent in shape and do not have

any voids, porosity, inclusions, or defects.
 This is especially helpful in later finishing and coating

operations as surface preparation is minimized.
 Parts that are produced by this method have high

strength to weight ratio and therefore used in the
design of the aircraft frames.
 It offers low cost for moderate to long runs.

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Outline
1 Metallurgical Basics
2 Forging Operation
3 Machinery
4 Design
5 Application
6 Die Forming Forces
7 Economics

PE4652 – Teknologi Manufaktur 5
Forgeable materials I
All metals and metal alloys, with very few exceptions, are suitable for forging

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Forgeable materials II

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

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Grain-flow I
In an optimal forming process, this grain-flow is retained and runs parallel to
the surface of the component.
Optimal grain-flow increases the dynamic strength of the component

Grain-flow II
Grain-flow breaking out of the side would result in an
undesirable stress-raising notch effect.
The gear profile is milled in the two collars. In the area of the teeth, the grain-flow
is perpendicular to the direction of the load

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Outline
2 Forging Operation
3 Machinery
4 Design
5 Application
7 Economics

Forging Processes
Five main methods are
used in forging:
- Drop-forging
- Upsetting
- Extrusion
- Open-die forging
- Ring rolling
Drop-forging Upsetting
Extrusion Open-die forging Ring rolling

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Special forging processes
These special processes

are largely used for the
mass production of
families of similarly
shaped parts

Roll Forging

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Processes prior to forging I
Sawing offers the Cold shearing has the Hot shearing is

advantage of the advantages of low independent of material
greatest precision and material wastage and hardness and is well suited
the largest cross- short cycle times. The for integration into high
sections, but has disadvantage is that the speed automated forging
higher material cross-sectional area is lines
wastage, longer cycle limited (to max.
times and higher 150mm)
costs.

Processes prior to forging II
Inductive heating equipment
Inductive heating of cut-off blanks to a forging

temperature of approx. 1,250 oC

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Process stages in manufacture
Production stages of a drop-forged

crankshaft form left to right:
 Steel blank
 Pre-formed blank
 Rough-forged part
 Finish-forged part
 Forging and trimmed
 flash
 Crankshaft

Process steps after forging
Flash and piercing-slugs

are removed by trimming
and hole-piercing.
Post-forging processes
save material and
processing costs, reduce
the dimensional variation
and make possible
undercuts

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Tooling for forging
Open-die forging
Various forms of saddle Drop-forging: typical types of die

Toolroom: manufacture of dies and other tooling
The form of a die is produced either by spark-erosion or by high-speed milling. The

surface of the form is treated is various ways to improve its life (e.g. by grinding,
polishing, nitriding and/or hard-chrome plating ).

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Outline
2 Forging Operation
3 Machinery
4 Design
5 Application
7 Economics

Forging machinery I
Three main types Of machine are used for Forging: energy-dependant ;
press-force-dependant ; machine-stroke- dependant

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Forging machinery II
The machine types are shown depicting the limiting conditions at the end of the
working stroke.

Hammers for drop forging I

1. Power unit
2. Ram
3. Upper die
4. Lower die
5. Anvil block
6. Vibration
damper
elements

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Hammers for drop forging II
1. Drive
2. Ram
3. Upper die
4. Hammer frame
5. Lower die
6. Lower ram
The counterblow hammer is 7. Hydraulic ram
driven pneumatically – ideal
for large pieceweights clutch

Presses for drop forging I
1. Frame
2. Punch slide
3. Punch guide
4. Screw spindle
5. Spindle nut
6. Clutch
7. Flywheel bearings
8. Spindle brake
Hydraulic
equipment
The screw press is suitable
for long runs and can be
9. Ejector
automated 10. Pneumatic
counterweight

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Presses for drop forging II
1. Hydraulic
cylinder
2. Ram
3. Table
4. Machine frame
5. Electric motors
6. Walking beam
automation
The hydraulic press offers a
constant maximum press 7. Forming station
force over the whole stroke
8. Material feed

Presses for drop forging III
The eccentric press is machine

stroke dependant and readily
automated at high rates of
production (strokes per minute)
1. Frame 6. Counterweight
2. Ram 7. Ram adjustment
3. Connecting rod 8. Reduction gearbox
4. Ram guide 9. Double-helical gearing
5. Clutch and brake system 10. Upper and lower ejector
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Automation of important forging equipment
1. Feed gripper
2. Transport
grippers
3. Lower die
4. Tongs arms
5. Tongs slide
6. System drive
unit
7. Transverse
slide
8. Press framer
Tongs arm system

Automated production line

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Outline
2 Forging Operation
3 Machinery
4 Design
5 Application
7 Economics

General rules of closed-die design

• The die set should be designed for smooth metal flow – symmetry dies
(spherical or blocklike) are the easier than thin and long section.
• Shape changes in section are to be avoided.
• Dies should be designed for the minimum flash to do the job.
• Generous fillet dimensions should be allowed, therefore, forging dies must
be tapered or drafted to facilitate removal of the finished piece.
• Draft allowance is approximately 3-5o outside and 7-10o inside.
• Dies with inclined angles should have counterlock to prevent the dies from
sliding apart from each other due to side thrust.

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Parting Line

Minimum Corner and Fillet Radii
Height, h 24 32 48 64 80 96 130 160 194

Rounded end
2 3 4 5 6 7 8 10 12
radius, r1
Inside fillet radius,
1.2 1.6 2 2.4 2.8 3.3 4 4.5 5
r2
Outside fillet radius,
0.8 1.2 1.6 2 2.4 2.8 3.3 3.6 4
r3
Corner radius, r4 3 4 5 6 7 7 8 8 10
In mm

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Die failures
• Different parts of dies are liable to permanent deformation and wear resulting from
mechanical and thermal fatigue.
• Important factors: shape of the forging, die materials, how the workpiece is heated,
coating of die surface, the operating temperature (should not exceed the annealing
temperature).

Die materials I
Required properties
• Thermal shock resistance Die materials: alloyed steels (with
• Thermal fatigue resistance Cr, Mo, W, V), tool steels, cast steels
• High temperature strength or cast iron. (Heat treatments such
• High wear resistance are nitriding or chromium plating
• Hgh toughness and ductility are required to improve die life)
• High hardenability
• High dimensional stability during hardening
• High machinability
Note:
1) Carbon steels with 0.7-0.85% C are appropriate for small tools and flat
impressions.
2) Medium-alloyed tool steels for hammer dies.
3) Highly alloyed steels for high temperature resistant dies used in presses and
horizontal forging machines.
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Die materials II
Die life can be increased by
1) Improving die materials such as using composite die or
2) Using surface coating or self-lubricating coatings

Outline
2 Forging Operation
3 Machinery
4 Design
5 Application
7 Economics

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Machining of forged parts

High-speed steel (HSS), tungsten carbide (TC) and ceramics are all used to
make cutting tools
Recommended cutting speeds for the machining of forgings

Diversity of forms in automotive manufacturing

In car manufacture special properties are required, which can be achieved using hot-,
warm- and cold-forging or a combination of several manufacturing steps.
Steel and aluminium Engine parts are mostly Gear-box parts made of
chassis made of steel -
components for car hot-forged steel hot-forged and cold-sized
manufacture

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Diversity of forms in automotive manufacturing
Forged components are ideal

for handling the extreme
mechanical and dynamic loading
on heavy construction machinery.
• Blade hinge
• Cylinder eye
• Scarifier tooth
• Drive sprocket
• Track guide
• Track idlers
• Track links

Use in aircraft manufacture

Alongside their use in jet
engines, forged
components are also
used in highly-loaded
areas such as wings,
rudders, control surfaces
and landing gear

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Outline
2 Forging Operation
3 Machinery
4 Design
5 Application
7 Economics

Analysis of Open-Die Forging

Upsetting or upset forging, reduces the height of the work and increases its diameter
Under these ideal conditions, the true strain experienced by the work during the process,
h0
  ln
h
ho = starting height of the work, mm; and
h = the height at some intermediate point in the process, mm.
hf = true strain reaches its maximum value
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Estimates of force to perform upsetting
F = Yf ·A
Where F = force, N
A = cross-sectional area of the part,mm2
Yf = flow stress, MPa
The strain-hardening exponent n = 0, and flow stress Yf equals

the metal’s yield strength Y

An actual upsetting operation
F = Kf ·Yf ·A
Where F = force, N
A = cross-sectional area of the part,mm2
Yf = flow stress, MPa
Kf = the forging shape factor

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The forging shape factor
0.4    D
K f  1
h
where μ = coefficient of friction

D = workpart diameter or other dimension representing contact
length with die surface, mm
h = workpart height, mm

Example :
A cylindrical workpiece is subjected to a cold upset

forging operation. The starting piece is 75 mm in height
and 50 mm in diameter. It is reduced in the operation to
a height of 36 mm. The work material has a flow curve
defined by K = 350 MPa and n = 0.17. Assume a
coefficient of friction of 0.1. Determine the force as the
process begins, at intermediate heights of 62 mm, 49
mm, and at the final height of 36 mm.

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Solution:
Workpiece volume V = 75π ·(502/4) = 147,262 mm3
At the moment contact is made by the upper die, h = 75 mm

and the force F = 0
At the start of yielding, his slightly less than 75 mm
assume that strain = 0.002
the flow stress is,

0.17
Y f  K n  3500.002  121.7 MPa

The diameter is still approximately D = 50 mm
area A = π(502/4) = 1963.5 mm2
For these conditions, the adjustment factor Kf is
0.4  (0.1)  50

K f  1  1.027
75
The forging force
F = Kf ·Yf ·A
F  1.027  121.7   1963.5  245.41 N

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75
At h = 62 mm,   ln  ln1.21  0.1904
62
Yf  350  0.1904   264 MPa
17
Assuming constant volume, and neglecting barreling,
A  147.262 / 62  2357.2 mm 2
4  2375.2 
D  55 mm

0.4  0.1  55
K f  1  1.035
62
F  1.035  264  2375.2  649.303 N
Similarly, at h = 49 mm, F = 955.642 N; and at h = 36 mm,
F = 1467.422 N.
The load stroke curve was developed from the values in this
example
Upsetting force as a function of height h and height reduction (ho - h).

This plot is sometimes called the load stroke curve.
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HW
Sebuah batang dikenakan proses forging upset

menggunakan open die. Do = 50 mm dan ho = 40 mm.
Ketebalan akhir = 20 mm. Koefisien friksi pada permukaan
die = 0,2. Material benda kerja mempunyai nilai flow curve
sebesar K = 600 MPa dan n = 0.12 .
1. Carilah gaya yang diperlukan untuk operasi:
a. Saat yield point dicapai (strain = 0.002)
b. h = 30 mm
c. h = 20 mm.
2. Bangunlah sebuah diagram yang menggambarkan
hubungan gaya operasi dengan ketebalan material yang
terbentuk menggunakan ms excel.

Outline
2 Forging Operation
3 Machinery
4 Design
5 Application
7 Economics

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Economics

Tool design and profitability

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Material Losses in Forging (1)
Shear loss : The blank required for forging a component is cut from
billets or long bars. Shear loss is generally taken as 5
percent of net weight.
Tonghold loss : Drop forging operations are performed by holding the

stock at one end with the help of tongs.
Tonghold loss = Area of X-section of bar × Length of tonghold
Scale loss : As the forging process is performed at very high

temperature, the Oxygen from air forms iron oxide by
reacting with hot surface. Scale loss is taken as 6 percent of
net weight.
Material Losses in Forging (1)
Flash loss : Flash is generally taken as 20 mm wide and 3 mm thick.

The flash loss in weight is then calculated by multiplying the
volume of flash by density of the material.
Sprue loss : When the component is forged by holding the stock with
tongs, the tonghold and metal in the die are connected by a
portion of metal called the sprue or runner. This is cut off
when product is completed. Sprue loss is taken as 7
percent of net weight.

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Estimation of Cost of Forgings
The cost of a forged component consists of following

elements :
o Cost of direct materials.
o Cost of direct labour.
o Direct expenses such as cost of dies and cost of
press.
o Overheads.

1. Cost of Direct Material

Cost of direct material used in the manufacture of a forged component
is calculated as follows :
Calculate the net weight of forging :

Net weight of the forged component is calculated from the drawings by first
calculating the volume and then multiplying it by the density of
material used.
Net weight = Volume of forging × Density of material
Calculate the gross weight :

Gross weight is the weight of forging stock required to make the forged
component.
Gross weight = Net weight + Material loss in the process

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Diameter and length of stock : The greatest section of forging gives the
diameter of stock to be used,
Gross weight
Length of stock 
X - sectional area of stock  Density of material
The cost of direct material is calculated by multiplying the gross weight by

price of the raw material
Direct material cost = Gross weight × Price per kg

2. Cost of Direct Labour
Direct labour cost is estimated as follows :
Direct labour cost = t × l
t = time for forging per piece (in hours)
l = labour rate per hour.

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3. Direct Expenses
Direct expenses include the expenditure incurred on dies and other equipment,
cost of using machines and any other item, which can be directly identified with
a particular product.
Apportioning of Die Cost

cost of Die = Rp. X
No. of components that can be produced using this die (i.e., die life) = Y components
Cost of die/component = Rp. X/Y

Apportioning of Machine (Press) Cost
Let cost of press = Rp. A

Life of press = n years
= n × 12 × 4 × 5 × 8 = 1920n hours
A
Hourly cost of press 
1920  n
No. of components produced per hour = N
A
Cost of using press per component 
1920  n  N
This excludes cost of power consumed and cost of consumables

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4. Overheads
The overheads include supervisory charges, depreciation of plant and

machinery, consumables, power and lighting charges, office expenses
etc. The overheads are generally expressed as percentage of direct
labour cost.

The total cost of forging is calculated by

adding the direct material cost, direct labour
cost, direct expenses and overheads.

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Example
Calculate the net weight and gross weight for the component shown in below.
Density of material used is 7.86 gm/cc. Also calculate :
Length of 14 mm dia bar required to forge one component.
Cost of forging/piece if :
Material cost = Rp. 16000 per kg
Labour cost = Rp. 1000 per piece
Overheads = 150 percent of labour cost.

Solution :
Net volume of forged component=
Net weight = 56.76 × 7.86 = 446 g
Losses :
Shear loss = 5 percent of net weight
Scale loss = 6 percent of net weight

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Taking flash width = 20 mm

Flash thickness = 3 mm
Flash loss = (periphery of parting line) × 2 × 0.3 × 7.86

= [2 (2 + 2.5 + 2 + 5) + 1.4 + (2 – 1.4) + (3 – 2) + (4 – 3) + 4] × 2 × 0.3 × 7.86
= 31.0 × 2 × 0.3 × 7.86 = 146 g
Tonghold loss = 2 × Area of cross-section of bar × 7.86

= 2 × π/4(1.4)2 × 7.86 = 24.22 g
Sprue loss = 7 percent of net weight

=7/100 × 446 g
= 31.22 g

Total material loss = 22.3 + 26.8 + 146 + 24.22 + 31.22

= 250 gms
Gross weight = Net weight + Losses
= 446 + 250 = 696 g
New length of 14 mm f bar required per piece

Volume of forging

Area of X – Section of bar
56.76
  36.86 cm
  1.42
4

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Direct material cost = 696/1,000 × 16000
= Rp. 11136
Direct labour cost = Rp. 1000 per piece
Overheads = 150 percent f labour cost
= 1.5 × 1000 = Rp. 1500
Cost per piece = 11136 + 1000 + 1500
= Rp. 13636

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4/10/2017

PE4652 – Teknologi Manufaktur

• Forging is manufacturing process

TEKNIK DAN SISTEM PRODUKSI

TEKNIK DAN SISTEM PRODUKSI

 The forgings are consistent in shape and do not have

 This is especially helpful in later finishing and coating

 Parts that are produced by this method have high

 It offers low cost for moderate to long runs.

TEKNIK DAN SISTEM PRODUKSI

6 Die Forming Forces

TEKNIK DAN SISTEM PRODUKSI

TEKNIK DAN SISTEM PRODUKSI

TEKNIK DAN SISTEM PRODUKSI

• Parts have good strength

TEKNIK DAN SISTEM PRODUKSI

Optimal grain-flow increases the dynamic strength of the component

TEKNIK DAN SISTEM PRODUKSI

TEKNIK DAN SISTEM PRODUKSI

6 Die Forming Forces

TEKNIK DAN SISTEM PRODUKSI

Extrusion Open-die forging Ring rolling

TEKNIK DAN SISTEM PRODUKSI

Special forging processes

These special processes

TEKNIK DAN SISTEM PRODUKSI

TEKNIK DAN SISTEM PRODUKSI

Processes prior to forging I

Sawing offers the Cold shearing has the Hot shearing is

TEKNIK DAN SISTEM PRODUKSI

Processes prior to forging II

Inductive heating equipment

Inductive heating of cut-off blanks to a forging

TEKNIK DAN SISTEM PRODUKSI

Process stages in manufacture

Production stages of a drop-forged

TEKNIK DAN SISTEM PRODUKSI

Process steps after forging

Flash and piercing-slugs

TEKNIK DAN SISTEM PRODUKSI

Tooling for forging

TEKNIK DAN SISTEM PRODUKSI

Toolroom: manufacture of dies and other tooling

The form of a die is produced either by spark-erosion or by high-speed milling. The

TEKNIK DAN SISTEM PRODUKSI

6 Die Forming Forces

TEKNIK DAN SISTEM PRODUKSI

TEKNIK DAN SISTEM PRODUKSI

TEKNIK DAN SISTEM PRODUKSI

Hammers for drop forging I

TEKNIK DAN SISTEM PRODUKSI

Hammers for drop forging II

TEKNIK DAN SISTEM PRODUKSI

Presses for drop forging I

TEKNIK DAN SISTEM PRODUKSI

Presses for drop forging II

TEKNIK DAN SISTEM PRODUKSI

Presses for drop forging III

The eccentric press is machine

Automation of important forging equipment

TEKNIK DAN SISTEM PRODUKSI

Automated production line

TEKNIK DAN SISTEM PRODUKSI