Forging pdf

That is, a greater percentage deforms work piece while others are lost in the form of noise, foundation shock, noise and heat. This makes it important to define the fraction of energy generated by hammer that is utilized efficiently. Normally, the efficiency is defined by the magnitude of deformation that takes place during any stroke.

This can be defined in the range: 0. The efficiency of the forging hammer is based on the analysis of the amount of energy generated and the amount utilized. Where, w is the weight of the hammer, A is the area of the piston, P is the steam or air pressure while H is the drop height. However, it is important to note that the initial cost of the forging equipment is slightly expensive. These machines use hydraulic pressure to move the piston. These machines are also associated with longer contact time, especially at the die and metal interface.

Hydraulic presses are more accurate. This is the main reason why they are used in applications that require very tight tolerances. Again, it is worth noting that, they are more expensive than hammers and mechanical presses.

These machines have crank presses with the ability to translate rotary motion to a reciprocating linear motion. Depending on specified requirements, this will result in a total energy that can forge a work piece. Mechanical presses are distinguished by the fact that, their ram stroke is relatively shorter than either the hydraulic press or hammer. In most cases, these presses are always rated based on the magnitude of force they can develop at the end of each stroke.

In most cases, establishing the right force should be based on the following key criteria:. Drop Forging Hammers. Forging Machinery. This implies, one has to be very specific on chemical and physical properties of the individual metals. It is a copper alloy that offers a wide range of benefits and has been incorporated in a number of applications. These are some of the main reasons why brass is commonly used in a number of industrial applications. It is the most forgeable. There are quite a number of alloy steel forging that are used in different manufacturing industries.

Some of the most popular alloys include the , and There are other types of steels with nearly the same chemical and physical properties. However, there are some variations based on the elements contained. Steel forging companies can choose from three main types of steels:.

Carbon steels have similar properties of iron. Adding more carbon makes it difficult to weld or deform and cracks easily. Which will make it difficult to forge. Alloy steels have greater strength, hardness, wear resistance and enhanced toughness. Often you may need additional heat treatment to achieve all these. Stainless steels contain higher amount of chromium.

They are corrosion resistant and do not rust. It is upon the metal fabrication technician to opt for a metal that suits a specific application. By adopting right technique, metal forging company can produce stronger and durable steel parts than cast or machined parts. With right forging technique , steel parts will possess the following key properties:. Forged steel parts are used in a wide range of applications that may include manufacturing cranes, cables, hydraulic press, shafts and axles for drives.

Aluminum has become popular across very many industries due to its light weight. Check one list from slideshare. Aluminum forging is popular due to the superior physical and chemical properties. This makes it a perfect choice for a number of applications such as automotive, wheels, airframes and panels. This is the main reason why they are used in the petrochemical and marine industries. In fact, most fasteners in these industries are manufactured from aluminum.

It is a versatile metal that be manufactured with a wide range of metal forging processes. Its soft compared to other materials such as iron. This reduces the production cost. In most industries, iron is considered a super alloy. This is due to the fact that, the forged parts are mainly used in high temperature applications.

Iron forged parts are less expensive as compared to other alloys such as the nickel or cobalt-based alloys. In addition to these, the iron based alloys can be hot or cold worked. This will depend on the final physical and chemical properties that one wishes to achieve.

Iron forging is a manufacturing technique used to produce parts that should meet the following key criteria:. Choosing a particular type of iron alloy for any forging process should be based on the desired applications. It is known for its non-magnetic, corrosion resistance, machinability, ductility, malleability and wear resistance. Again, the parts can withstand high stress without unexpected failures. In most cases, Forged copper parts are highly recommended. Stainless steel, which is available in , , and ,can be open die forged into different shapes.

In normal industrial setup, parts that can be obtained include: copper discs, shafts, rings, plates, etc.

The forged stainless steel parts can withstand sanitizing and frequent cleaning; this is one of the main reasons why it is used in the food processing and medical equipment. Highly resistant to corrosion; this is the main reason why it is used in petrochemical, marine and chemical industries, especially in pumps.

These parts can withstand prolonged exposure to corrosive environment. The forged parts have high resistance to heat. This makes it a perfect choice for furnace, heat sinks and ovens.

They guarantee high wear and high performance. This explains the reason why they are used for landing gears and motor components. The forged parts have high stability and strength. This makes it a perfect choice for most structural components. In short, stainless steel is one of the most popular materials used to manufacture a number of industrial parts. This is because having some of the best physical and chemical properties. Ideally, the main advantages and disadvantages of the process can be discussed based on the type of the forging process.

May be, we need to clarify these terms first before we look at the advantages and disadvantages of each process. The metal is subjected to compressive forces at temperatures below the recrystallization temperature. The most common process that is used is the impression- die casting. It is a perfect choice for soft metals. The parts have increased ductility and strength; this makes them a perfect choice for most applications.

Flexibility; hot forging is more flexible than cold forging. This is because customized parts can be manufactured easily. Superior surface finish; this allows for a number of finishing operations such as painting, coating or polishing. H igh temperature removes any homogeneous substances. This is due to the increased diffusion. There is a reduction in the pore size. Therefore, it is important that one evaluates both the advantages and disadvantages of the two processes.

This is an effective way to adopt a reliable, efficient and cost effective metal forging technique. Advantages and disadvantages of closed die forging. Open die forging is process of plastically deforming the metal by subjecting to a series of compressive forces. Dies, which is also referred to as the hammer, deform materials through a series of movements.

Forgings that can be obtained from this process may range from a few pounds to tons. In fact, more sophisticated machines can forge even larger parts. Normally, the work piece is held between flat faced dies. Generally, all forgeable non-ferrous and ferrous alloys can be processed through this manufacturing process.

Nearly all products forged through open die forging technique require secondary operations. In most cases, the metal may be heated above the recrystallization temperature. These may include discs, sleeves, shafts, cylinders or shafts. Since the products is deformed repeatedly, the final product has an improved grain structure.

In an advanced metal forging process, the open die forging can be tailored to meet different requirements. Prakasan Slide share documents : forming process forging. Metal can be heated to temperature above the recrystallization temperature.

This is always referred to as hot forging. This eliminates the work hardening problems. Temperature is below the recrystallization temperature. This is typically referred to as the cold forging.

Also referred to as the free forging. In this metal forging, metal is subjected to a compressive force without being confined within dies. Video: Drop Forging process. Drop Forging — Introduction. Forging Course from nptel. The process varies slightly from the drop-hammer forging in that, the work piece is subjected to a slow but continuous force.

No need for the heavy and quick blows. In fact, the time tool gets in contact with work piece is longer — about several seconds. Press forging has become popular across very many industries. It changes both surface and interior of work piece. In contrary, drop forging only deforms the surface. This process is more controlled, thus, it becomes easy to examine crucial aspects of the forging process. A good example is examining the strain rate. The process is also efficient and reliable. In addition to these, in press forging, the energy is optimally utilized.

The Advantages and Disadvantages of Press Forging. Video : Ton large forging press. What is the difference between press forging and drop hammer forging? In this process, the preheat metal is held between the grooved dies. Heading Or Upset Forging. Normally, these are two opposing rollers that subject work piece to a desired compressive force that is just enough to deform it. This process is carried out above the recrystallization temperature hot forging process.

Roll Forging. Video : Ring Roll Forging. Choice of a particular process will mainly depend on the specific manufacturing objectives one would wish to achieve. We shall also highlight some of the main reasons why you need to adopt a specific casting or forging for a given application. In metal casting, metal is heated to a molten state, poured into a mold to create a desired shape. Forging Forging is the process of manipulating the shape of a metal by subjecting it to compressive forces.

A die is used to transform the metal into a desired shape and size. Distinct facts about forging. Above are clear differences between forging and casting. Manufacturers should choose a technique based on quality of final products.

Forging vs. Casting: Which is better? Steel Fabrications vs. Items include components used in both light and heavy machines that are used in different industries. Examples of parts include: automatic and manual transmission systems, steering parts, engine parts, etc. Examples include: inner-outer ring, taper roller bearing outer ring, bearing and other engine and transmission parts.

Others include engine discs, compressor parts, exhaust, spinners and other aircraft structural parts. Forged parts include turbine components, discs, shafts, seamless pipes and fittings, just to mention a few. Forged precision parts include: bars, welding products, gaskets, washers, etc. This is mainly due to their structural integrity. A number of medical equipment are forged. These include trauma parts, extremities parts, implants and medical machine parts.

Generally, precision forging has become part of our daily life. All that matters is the ability to get quality products that can meet the specific requirements of the end users. Like other professions, a number of stakeholders and companies have formed associations that oversee how people go about their business in the forging industry. Moreover, they provide educational materials and avenues of connecting all metal forging companies globally.

Apparently, there are over ordinary members and about 45 Associate Members of the Association. The members include corporations, companies, person or firms. AIFI enhances skills and promotes professionalism.

This is through educational videos and publications. AIFI also participate in both national and international seminars. Soon, members will also be able to advertise with AIFI. FIA provides a wide range of information aiming to increase global competitiveness in the forging industry. It provides opportunities within the industry: career information, forge shop information and learning material.

It has about forging operations. CFIA organizes conferences, exhibitions, publishes magazines, oversees research and avails learning resources. The association champions for cost effective and sustainable forging processes. Generally, there are many forging associations in the world today. It is important that one becomes a member of this a forging association, especially those who are in the forging industry.

Metal forging is an integral part of any manufacturing process in the modern industrial setup. It is important that one chooses an effective a reliable technique based on the specific requirements of the end user. When you know all aspects of metal forging , you will benefit a lot if your product parts made from the metal forging process. A leading brass casting solution provider, Gaton Brass specializes in brass die casting, brass forging, lost wax casting, sand casting and milling.

As the premier brass parts manufacturer and foremost foundry of brass in China, Gaton Brass has succeeded in the lighting, auto, electrical, home furniture, gift and marine industries. We are proud of our tooling quality which creates product quality. Based on this philosophy, we started building the tooling library, our in-house tooling facility 20 years ago.

This has helped over clients save cost appreciably. Your Name required. Your Email required. Your Comments. In this eBook, we will explain you all aspects of metal forging. It is designed for both experts and non-experts in the forging industry.

We aim to provide you the basic and advanced foundation of metal forging. The force changes the shape of the metal to form the desired shape. Basically, forging is an example of deformation process.

The process is classified based on an environment the manufacturing process takes place. You will understand it in next chapter. Chapter 2: Forging Process Traditional vs. In fact, the tools that were used before Homo sapiens existed were produced by metal forging. It is one of the oldest metal working arts.

In fact, these were very rudimentary tools ever created by the ancient man. The early man depended on a rudimentary manufacturing process. That is, they could deform material parts using bare hands. Apparently, this no longer the case. Modern forging machines are effective and efficient. This is due to the wide range of benefits it has to offer. Machines that are used in modern part processing are efficient, reliable and more sophisticated.

This guarantees a high level of accuracy and precision. This is due to the plastic deformation. Normally, it is used to process all metals such as steel, iron, brass, etc. At times, they may not be manufactured using a single metal forging technique. Check 3 most important ones: Complexity of the metal part.

Types of material metal. Technique to be used. That is, the orientation of grain pattern may change. During forging process, metal can be subjected to a number of processes. This aims to transform the material to a desired shape. Some key operations include: 1. You also need a deep drawing to confirm the follow thing: Wall thickness of the final product. Degree of tolerance. Radius of the final product Work hardening At times, deep drawing may not be a single process.

Up-setting This forging technique is mainly used to increase the cross sectional area of metal at the expense of length. Up-setting force can be applied in the direction that is parallel to the length axis. It is commonly used in manufacturing processes such as production of bolts. Fullering In this metal forging technique, the cross-sectional area of metal decreases as the length of the metal is increased.

At the same time, the stock heated as the fuller top is kept above the stock. This technique is commonly used to make the internal combustion of engines. Edging It is one of the most common type of drop forging operation. Generally, the metal flow is always confined in the horizontal direction. Bending This is one of the most common forging operations. It is mainly needed for those parts that should be used near bends. It is commonly used to produce holes in the work piece.

Forged welding This is used to refer to the process of joining two metals. It aims at increasing the length of metal. You can achieve this through hammering or pressing.

The process is carried on a forging shop, hence the name forged welding. Cutting This process is mainly used to separate materials into pieces. In most cases, a hammer or chisel. It is mainly used to eliminate the corrugated surface of the final product.

It is mainly used to obtain a smooth surface. Swaging This manufacturing process is suitable in operations where the length of the final product should be reduced to a desired shape. One particular variant, drop forging, is often used to mass produce flat wrenches and other household tools. A forge which typically uses bituminous coal, industrial coke or charcoal as the fuel to heat metal. The designs of these forges have varied over time, but whether the fuel is coal, coke or charcoal the basic design has remained the same.

A forge of this type is essentially a hearth or fireplace designed to allow a fire to be controlled such that metal introduced to the fire may be brought to a malleable state or to bring about other metallurgical effects hardening, annealing, and drawing temper as examples. During operation, fuel is placed in or on the hearth and ignited. A source of moving air, such as a fan or bellows, introduces additional air into the fire through the tuyere.

With additional air, the fire consumes more fuel and burns hotter. A blacksmith balances the fuel and air in the fire to suit particular kinds of work. Often this involves adjusting and maintaining the shape of the fire. In a typical, but by no means universal, coal forge, a firepot will be centered in a flat hearth. The tuyere will enter the firepot at the bottom. In operation, the hot core of the fire will be a ball of burning coke in and above the firepot.

The heart of the fire will be surrounded by a layer of hot but not burning coke. Around the unburnt coke will be a transitional layer of coal being transformed into coke by the heat of the fire. Surrounding all is a ring or horseshoe-shaped layer of raw coal, usually kept damp and tightly packed to maintain the shape of the fire's heart and to keep the coal from burning directly so that it "cooks" into coke first.

If a larger fire is necessary, the smith increases the air flowing into the fire as well as feed and deepen the coke heart. The smith can also adjust the length and width of the fire in such a forge to accommodate different shapes of work. The major variation from the forge and fire just described is a 'back draft' where there is no fire pot, and the tuyere enters the hearth horizontally from the back wall. Coke and charcoal may be burned in the same forges that use coal, but since there is no need to convert the raw fuel at the heart of the fire as with coal , the fire is handled differently.

Individual smiths and specialized applications have fostered development of a variety of forges of this type, from the coal forge described above, to simpler constructions amounting to a hole in the ground with a pipe leading into it. A forge typically uses propane or natural gas as the fuel. One common, efficient design uses a cylindrical forge chamber and a burner tube mounted at a right angle to the body.

The chamber is typically lined with refractory materials, preferably a hard castable refractory ceramic. The burner mixes fuel and air which are ignited at the tip, which.

The air pressure, and therefore heat, can be increased with a mechanical blower or by taking advantage of the Venturi effect. Gas forges vary in size and construction, from large forges using a big burner with a blower or several atmospheric burners to forges built out of a coffee can utilizing a cheap, simple propane torch.

A small forge can even be carved out of a single soft firebrick. The primary advantage of a gas forge is ease of use, particularly for a novice. A gas forge is simple to operate compared to coal forges, and the fire produced is clean and consistent. They are less versatile, as the fire cannot be reshaped to accommodate large or unusually shaped pieces;.

It is also difficult to heat a small section of a piece. A common misconception is that gas forges cannot produce enough heat to enable forge-welding, but a well designed gas forge is hot enough for any task. The workpiece, say a wrench, is created by hammering a piece of hot metal into an appropriately shaped die.

The metal in an easily produced shape like a rod or brick is heated and placed on the bottom part of a die. The top part of the die then drops onto the piece, which gives the forge its name. The die may drop under gravity or be powered, but in all cases drop forging involves impact. The force of the impact causes the heated metal to flow into the shape of the die, with some metal squirting out of the thin seams between the dies.

This thin metal is called "flash" and is cut away in the next stage of processing. The drop-forged pieces usually need further processing, like machining and polishing of working surfaces, to provide tighter tolerances than forging alone can provide, and to produce a good finish. In hydraulic press forging the work piece is pressed between the two die halves with gradually increasing force, over a period of a few seconds.

The quality of the pieces is better than drop forging as there is more control over metal flow, but takes longer and requires more energy. It also makes the same shape continuously. Forging is the hammering or forming of hot or cold metal into a certain shape. When the hammering and forming is done by hand it is called hand forging and when it is done by machine it is called drop forging.

It allows us, through a process of reduction for crushing , to get the most various shapes. The anvil serves as a work bench to the blacksmith, where the metal to be beaten is placed. An anvil body is made of mild steel, with a top face of high carbon steel approximately 20mm thick welded on it.

The flat top has two holes; the wider is called the hardy hole, where the square shank of the hardy fits. The smaller hole is called the punch hole, used as clearance when punching holes in hot metal. Chisels are made of high carbon steel whose cross-section is an octagon. They are hardened and tempered at the cutting edge while the head is left soft so it will not crack when hammered.

Chisels are of two types, the hot and cold chisels. The cold chisel is used for cutting cold metals while the hot chisel is for hot metals. Usually the hot chisels are thinner and therefore can not be substituted with the cold chisel.

Tongs are used by the blacksmith for holding hot metals securely. The mouths are made in various shapes to suit the gripping of various shapes of metal. Fullers are forming tools of different shapes used in making grooves or hollows. They are often used in pairs, the bottom fuller has a square shank which fits into the hardy hole in the anvil while the top fuller has a handle.

The work is place don the bottom fuller and the top is placed on the work and struck with a hammer. The top fuller is also used for finishing round corners and for stretching or spreading metal. The hardy is a cutting tool similar to the chisel. It is used as a chisel or hammer for cutting both hot and cold metals. It has a square shank that fits into the hardy hole in the anvil, with the cutting edge facing upwards. The metal to be cut is placed on the cutting edge and struck with a hammer.

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Extrusion technology for the production of micro-aquatic feeds and shrimp feeds. Jump to Page. Search inside document. See Figure Figure - Flow lines in a forged part Normally this results in metallurgical soundness and improved mechanical properties. Types of forging: Forging is divided into three main methods: hammer, press, and rolled types.

Forging Equipment: The type of machinery to be used depends on the shape, size, material, and number of pieces to be made. Heat Treatment: Materials can be improved before or after manufacturing by different heat treatment processes. Gas forge A forge typically uses propane or natural gas as the fuel. Drop forge Hydraulic forging hammer The workpiece, say a wrench, is created by hammering a piece of hot metal into an appropriately shaped die.

Hydraulic press forge In hydraulic press forging the work piece is pressed between the two die halves with gradually increasing force, over a period of a few seconds. Finery forge A finery forge was a water-powered mill, where pig iron was refined to produce bar iron. Forging Equipment Anvil The anvil serves as a work bench to the blacksmith, where the metal to be beaten is placed. Chisel Chisels are made of high carbon steel whose cross-section is an octagon.

Tongs Tongs are used by the blacksmith for holding hot metals securely. Hardy The hardy is a cutting tool similar to the chisel. Documents Similar To forging. Anonymous 9xvU1F. Phan Trang. International Aquafeed magazine. Mohammad Zahidul Karim. DespachoLegal Cvo. Jai Patel. Vikram Borkhediya. Al Engg. Anonymous f1UCK4. Veerendranath Vasabathula. CORE Materials. Anonymous YkDJkSq. Mat Juri Liman. Chauhan Chetan. Popular in Building Materials.

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