Forging

Presented by:
M. Khoirul Effendi ST. MSc. (Eng.)
Hammer Forging

Forging is a deformation process in which the work is compressed between two

dies, using either impact or gradual pressure to form the part (for example
Hammer forging)
 Hasil Tempa
Products of Forging (1/2)

Connecting rod
and piston

crankshaft
Products of Forging (2/2)

gears

6
Microstructure as Function of
Manufacturing Methods

Schematic illustration of a part made by three different processes showing grain flow. (a) Casting by the
processes described in Chapter 11. (b) Machining form a blank, described in Part IV of this book, and (c)
forging. Each process has its own advantages and limitations regarding external and internal
characteristics, material properties, dimensional accuracy, surface finish, and the economics of production.
Source: Courtesy of Forging Industry Association.
Various Type of Forging (1/2)

/ closed die forging

Various Type of Forging (2/2)
General Characteristics of Forging
Open-Die /Upsetting Forging

 The simplest forging process

 Sizes can be varied from small parts to large
 the metal to flow without constraint in a lateral direction
Forging Force
Yf : flow stess of the
materials
Forging force, 𝐹 = 𝑌𝑓 𝜋𝑟 2 1+
2𝜇𝑟  : friction coefficient
3ℎ r : workpiece radius
b : workpiece height

(a) Upsetting: 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.
Flat Die Forging and Barreling

 Upsetting/flat-die forging  a solid workpiece is placed between flat

dies and compressed

 About Barreling
1. Caused by frictional force
2. Minimized by lubricant
3. Thermal effect generated by barreling is minimized by heated dies
Example
Answer (1/2)

At the end Assuming the total value is same, therefore

𝜋 (75)2 100 = 𝜋 (𝑟)2 50
Therefore r at the end process is 106 mm
100
Absolute strain 𝜀 = 𝑙𝑛 50 = 0.69
Based on absolute strain value, from table 2.3 for stainless steel 304

K = 1275 Mpa and n = 0.45

Answer (2/2)

2𝜇𝑟
𝐹 = 𝑌𝑓 𝜋𝑟 2 1+
3ℎ
2𝜇(0.106)
𝐹= 1000𝜋(0.106)2 1+
3(0.05)
= 45 MN
Various Types of Workpiece on
Open Die Forging

(a) Die forging to reduce the thickness of rectangular bar

(b) Die forging to reduce diameter bar
(c) Die forging to reduce thickness of ring
Impression Die Forging vs. Flash-
less/closed Die Forging

Comparison of closed-die forging with flash (a) and precision or flash less
forging (b) of a round billet.
Impression Die Forging

Stage in Impression die forging of solid round billet, where

the flash (an excess metal) should be trimmed off
Standard Terminology of Forging Dies

• Parting line  the plane that divides the upper die and lower die.
• Draft  the amount of taper on the sides of the part required to remove it from
• the die( 3o on aluminum and magnesium parts and 5o to 7o on steel parts).
• Webs  a thin portion of the forging that is parallel to the parting line,
• Rib  a thin portion that is perpendicular to the parting line.
• Webb and Rib  when thinner, these part features cause difficulty in metal flow
• Fillet and corner radii. Small radii tend to limit metal flow and increase stresses on
die surfaces during forging.
Impression Forging example (1/2)

Crankshaft manufacturing
Impression Forging (2/2)
Trimming

Trimming is an operation used to remove flash on the work part in

impression-die forging
Die Inserts

Die inserts used in forging an automotive axle housing

Forged rod vs. Cut rod

Comparison of metal grain flow in a part

that is: (a) hot forged with finish machining,
and (b) machined complete
Fullering, Edging, Cogging

(a) (b) (c)

a) Fullering  reduce the cross section and redistribute the metal

b) Edging  similar to fullering, except that the dies have concave
surfaces..
c) Cogging  reduce cross section and increase length.
Forging Force on Impression Die
Forging

F  kY f A

Yf : flow stess of the materials

A : projected area of the forging, including the flash
The Coining Process

(b) (b)
(a) Coining using open cold die forging
(b) Ancient coin (up), modern coin (down)
Note : Lubricant can’t be used in this process, why?
Die forging/upsetting for Heading (1/2)

(1) wire stock is fed to the stop; (2) gripping dies close on the stock and
the stop is retracted; (3) punch moves forward; and (4) bottoms to form
the head.
Die forging/upsetting for Heading (2/2)

Examples of heading (upset forging) operations: (a) heading a nail using

open dies, (b) round head formed by punch, (c) and (d) heads formed by
die, and (e) carriage bolt head formed by punch and die.
Blanking and Piercing

How to produce it?

Grain Flow Pattern In Forging
Producing a Stepped Pin

(a) The stepped pin: (b) Illustration of the manufacturing

steps used to produce the stepped pin.
Rotary Swaging

Swaging and radial forging are forging processes used to reduce the diameter of a
tube or solid rod.
a) Schematic illustration
of the rotary-swaging
process.
b) Forming internal
profiles on a tubular
workpiece by
swaging.
c) A die-closing swaging
machine showing
forming of a stepped
shaft.
d) Typical parts made by
swaging.
Tube Swaging

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.
Roll Forging

Roll forging is a deformation process used to reduce the cross section of a

cylindrical (or rectangular) workpiece by passing it through a set of
opposing rolls that have grooves matching the desired shape of the final
part.
Orbital Forging

In this process, deformation occurs by means of a cone-shaped upper die

that is simultaneously rolled and pressed into the work part
Die Materials and Lubrication in Forging

General Requirements for die materials are:

1. Strength and Toughness at elevated temperature
2. Hardenability and ability to harden uniformly
3. Resistance to mechanical and thermal shock
4. Wear resistance, particularly for abrasive wears

The function of Lubrication are:

1. Reduce friction and die wear
2. Acting as thermal barrier to slow down the cooling rate of workpiece
3. Parting agent to prevent sticking between dies and a workpiece.
Forge Ability

Which material has

the highest forge
ability?
Producing Dies

• Depend on its size, shape and particular operation in which die is

used (forging, casting, extrusion, powder metallurgy, plastic molding)
• Die sinking is a process to produce die cavity in a die block
• Hubbing is a common method to produce small dies with shallow
cavities
• Dies are usually heat treated for higher harness and resistance.
• Most commonly dies is machined from forged die block using milling,
turning, grinding, EDM and ECM.
Hubbing

Hubbing is a deformation process in which a hardened steel form pressed

into a soft steel (or other soft metal) block. (1) before deformation, and (2) as
the process is completed.
 Defect on 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.
Die Failures

• Improper die design

• Improper die material
• Improper manufacturing, heat treatment, finishing operation
• Overheating and heat checking
• Excessive wear
• Overloading
• Improper alignment of die component with respect to its movement
• Misuse and Improper handling of the die
Typical Speed Ranges of Forging
Equipment
Various of Forging Process (1/2)

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

Hydraulic press. (b) 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.
Various of Forging Process (2/2)

Schematic illustration of the principles of various forging machines. (c)

Knuckle-joint press. (d) Screw press. (e) Gravity drop hammer
Mechanical Press With Eccentric Drive

Warm forming line

comprising a multiple-
station press with
eccentric drive (nominal
press force 20,000 kN,
induction furnace,
transfer feed and die
change support)
Knuckle-Joint Press

Knuckle-joint press with bottom drive (nominal

press force 6,300 kN, four stations with
transfer feed)
Screw Press

Multiple-station
press with modified
knuckle- joint top drive
(nominal press force
10,000kN, four stations,
loading system and
transfer feed)
Hydraulic Press

Hydraulic multiple- station

press (nominal press force
20,000 kN, four stations,
loading system, transfer
feed and die change
support)
Drop Forging Hammer

Drop forging hammer, fed by conveyor and heating units at the right of
the scene.
Forging Machines Comparisons

Forging Types Advantages Disadvantages

Hydraulic • Operate and constant • Load limited
controlled-speed • Higher initial cost
• Less maintenance
Mechanical Press • High production rates • Variation of speed and
(Eccentric & • Easy to be automated press (max at end of
Knuckle joint) • Require less operator skill stroke)
• Stroke limited
Screw Press • Suitable for small, and thin • Energy limited
part with high precision (i.e.,
turbine blade)
Hammer • Least expensive • Operates at high speed
• Die breakage and safety
consideration
 Cost in Forging

Typical (cost-per-piece) in forging; note how the setup and the tooling costs
per-piece decrease as the number of pieces forged increases if all pieces use
the same die.
Cost Comparison of Producing a Rod

Relative unit costs of a

small connecting rod
made by various forging
and casting processes.
Note that, for large
quantities, forging is more
economical. Sand casting
is the most economical
process for fewer then
about 20,000 pieces.
 A Case Study : Lotus Elise Series 2 and
Vertical Suspension Uprights

(a) The Lotus Elise Series 2 Sportscar; (b) illustration of the original design for the
vertical suspension uprights, using an aluminum extrusion; (c) retrofit design, using a
steel forging; (d) optimized steel forging design for new car models.
Comparison of Suspension on Design for
Lotus
Forging Practice and Product Quality(1/2)

1. Clean surface the raw material, (slug billet etc.) for example by shot
blasting
2. Concerning about scaling problem.
3. Pre-heat and lubricate the dies for hot forging, where lubricate the
blank for cold forging
4. Forge the material in appropriate dies and proper sequence. Remove
flash by cutting process.
5. Clean, check and machining to achieve the desired dimension
6. Performing heat treatment to improve its mechanical properties
7. Inspect the forging for any internal/external defects
Forging Practice and Product Quality(2/2)

Blank in cold forging Shot blasting