FUNDAMENTAL MANUFACTURING PROCESSES. Forging

Transcription

1 FUNDAMENTAL MANUFACTURING PROCESSES Forging SCENE 1. CG: FBI warning white text centered on black to blue gradient SCENE 2. CG: disclaimer white text centered on black to blue gradient WARNING federal law provides severe civil and criminal penalties for the unauthorized reproduction, distribution or exhibition of copyrighted videotapes SME Always read the operating manual and safety information provided by the manufacturer before operating any forging equipment. Make sure all machine guards are in place, and follow all safety procedures when working with or near forging equipment. SCENE 3. tape 40, 01:00:00-01:00:12 SME logo SCENE 4. tape 25, 01:01:00-01:01:20 fundamental series open tape 63, 12:06:32-12:09:06 open music MUSIC UP AND UNDER THE FUNDAMENTAL MANUFACTURING PROCESSES VIDEO SERIES, EXAMINING THE TOOLS AND TECHNIQUES OF PRECISION MANUFACTURING. SCENE 5. program title: CG: Forging white text centered on black THIS PROGRAM EXPLORES THE BASICS OF FORGING. SCENE 6. tape 480, 12:09:20-12:09:29 forging of part FORGING IS THE CONTROLLED DEFORMATION OF METAL INTO SPECIFIC SHAPES BY THE USE OF COMPRESSIVE FORCES.

2 SCENE 7. tape 480, 12:14:23-12:14:33 forging in hammer tape 485, 11:05:40-11:05:48 forging in press THESE FORCES ARE APPLIED THROUGH TOOLS AND DIES DRIVEN MAINLY BY HAMMERS, WHICH DEFORM THE WORKPIECE BY HIGH VELOCITY IMPACT, OR PRESSES, WHICH DEFORM THE WORKPIECE THROUGH CONTROLLED HIGH PRESSURES. SCENE 8. tape 404, 09:11:37-09:11:49 blacksmith at greenfield village FORGING IS ONE OF THE OLDEST METALWORKING PROCESSES, DATING AS FAR BACK AS 8000 B.C. SCENE 9. tape 484, 15:02:39-15:02:53 zoom in, open die forging operation, reducing cast ingot into wrought mill form tape 484, 15:14:19-15:14:35 ring rolling operation on wrought mill form IT IS UTILIZED TODAY TO REDUCE THE CROSS-SECTION, IMPROVE THE METALLURGICAL MICROSTRUCTURE, PROVIDE DIRECTIONAL GRAIN FLOW AND ELIMINATE POROSITY OF CAST INGOT IN FABRICATING WROUGHT MILL FORMS; AND TO FORM DISCRETE PARTS TO NEAR-NET SHAPE FROM THESE WROUGHT MILL FORMS, FURTHER REFINING MICROSTRUCTURE AND DIRECTIONAL GRAIN FLOW. SCENE 10. tape 468, 00:01:15-00:01:23 GRAPHIC: cutaway of wrought part showing directional properties tape 480, 12:21:19-12:21:24 forging of part tape 452, 19:18:52-19:19:04 casting operation BECAUSE OF THESE EFFECTS ON MICROSTRUCTURE AND GRAIN FLOW, THE MECHANICAL PERFORMANCE OF WROUGHT MILL FORMS AND PARTS IS TYPICALLY SUPERIOR TO THAT OF CAST METALS. SCENE 11. tape 485, 11:07:18-11:07:36 forging of part CG, SUPER: Forgeability tape 480, 12:17:31-12:17:43 bar stock being forged CG, SUPER: Forgeability Excellent Or High Good Fair ALL METALS AND ALLOYS ARE FORGEABLE. THE EXTENT TO WHICH THEY CAN BE FORGED, OR DEFORMED WITHOUT FRACTURE, IS CALLED FORGEABILITY. FORGEABILITY IS A QUALITATIVE RATING EXPRESSED IN TERMS SUCH AS

3 Poor Or Low EXCELLENT OR HIGH, GOOD, FAIR, AND POOR OR LOW. SCENE 12. tape 488, 00:16:00-00:16:10 c.u. open die forging CG, SUPER: Forgeability Metal s/alloy s Composition Crystal Structure Mechanical Properties tape 480, 12:29:20-12:29:34 part place into tooling and forged FORGEABILITY DEPENDS ON THE METAL S OR ALLOY S COMPOSITION, CRYSTAL STRUCTURE AND MECHANICAL PROPERTIES, AND PERTAINS TO A SPECIFIC TEMPERATURE RANGE. THE GREATER THIS TEMPERATURE RANGE THE BETTER SINCE NARROW RANGES ARE MORE DIFFICULT TO MAINTAIN DURING THE PROCESS. SCENE 13. tape 485, 11:08:00-11:08:08 forging on heated workpiece tape 489, 12:01:32-12:01:44 cold forging operation SINCE HEAT INCREASES FORGEABILITY MOST FORGING IS DONE ON HEATED WORKPIECES. HOWEVER FORGING CAN BE PERFORMED AT ROOM TEMPERATURE, WHICH IS CALLED COLD FORGING. SCENE 14. tape 492, 21:06:49-21:07:11 preforms being produced CG, SUPER: Aluminum Alloys Copper Alloys Magnesium Alloys Carbon Steels Low & High Alloy Steels Nickel Alloys Titanium Alloys ALUMINUM ALLOYS, COPPER ALLOYS AND MAGNESIUM ALLOYS RANK HIGH IN FORGEABILITY, FOLLOWED BY PLAIN CARBON STEELS, LOW AND HIGH ALLOY STEELS, NICKEL ALLOYS AND TITANIUM ALLOYS. SCENE 15. tape 363, 02:04:52-02:05:13 3 shots, forging of superalloy CG, SUPER: Superalloys Refractory Metals Beryllium SOME SUPERALLOYS, ESPECIALLY CERTAIN NICKEL-BASED TYPES, ARE MORE DIFFICULT TO FORGE. REFRACTORY METALS HAVE GOOD TO FAIR FORGEABILITY DEPENDING ON THE METAL OR ALLOY. BERYLLIUM IS THE LEAST FORGEABLE METAL. SCENE 16. continue previous shot tape 468, 00:09:00-00:10:00 blue background HOT-FORGING TEMPERATURES RANGE FROM AS LOW AS 93

4 CG: 93 Degrees Celsius Aluminum Alloys 1650 Degrees Celsius Refractory-Metal Alloys DEGREES CELSIUS FOR ALUMINUM ALLOYS, TO AS HIGH AS 1650 DEGREES CELSIUS FOR REFRACTORY-METAL ALLOYS. SCENE 17. tape 488, 00:02:58-00:03:08 open-die forging CG, SUPER: Open-Die Forging tape 481, 13:17:22-13:17:26 impression-die forging CG, SUPER: Impression-Die Forging THERE ARE TWO PRIMARY TYPES OF FORGING: OPEN-DIE FORGING..., AND IMPRESSION-DIE FORGING. BUT THERE ARE ALSO OTHER RELATED FORGING PROCESSES. --- FADE TO BLACK --- SCENE 18. CG: Open-Die Forging white text centered on black SCENE 19. tape 484, 15:04:07-15:04:22 open-die forging of ingot OPEN-DIE FORGING IS PERFORMED ON INGOT, BILLET, BAR OR A PREFORM, AND IS THE DEFORMATION OF A WORKPIECE BETWEEN FLAT OR SHAPED DIES WITHOUT COMPLETELY RESTRICTING METAL FLOW. SCENE 20. tape 478, 05:23:02-05:23:18 open-die forging, lengthening workpiece while reducing its cross section tape 488, 00:09:22-00:09:31 open-die forging, upsetting regions along workpiece length to greater sizes than adjacent regions tape 484, 15:15:41-15:15:48 open-die forging, bulging crosssection while reducing its length THIS DEFORMATION CAN RESULT IN LENGTHENING OF THE WORKPIECE WHILE REDUCING ITS CROSS SECTION, UPSETTING REGIONS ALONG THE LENGTH TO GREATER SIZES THAN ADJACENT REGIONS..., OR BULGING THE WORKPIECE S CROSS-SECTION WHILE REDUCING ITS LENGTH. SCENE 21. tape 488, 00:12:48-00:13:06 workpiece being lengthened or upset, incrementally advanced lengthwise and rotated about its LENGTHENING AND UPSETTING ARE TYPICALLY DONE USING

5 longitudinal axis MULTIPLE IMPACTS AS THE WORKPIECE IS INCREMENTALLY ADVANCED LENGTHWISE AND ROTATED ABOUT ITS LONGITUDINAL AXIS. SCENE 22. tape 488, 00:08:00-00:08:28 open-die forging of large part THERE IS ESSENTIALLY NO LIMIT TO THE SIZE OF FORGINGS THAT CAN BE MADE USING OPEN-DIE FORGING. THEY CAN RANGE FROM A FEW CENTIMETERS TO THIRTY METERS IN LENGTH, AND WEIGH FROM A FEW TO UP TO SEVERAL HUNDRED THOUSAND KILOGRAMS. SCENE 23. tape 488, 00:15:35-00:15:48 complex shapes being produced using open-dies tape 478, 05:30:55-05:31:04 open-die forging tape 479, 06:04:56-06:05:04 simple forged solids ALTHOUGH FAIRLY COMPLEX SHAPES CAN BE MADE USING OPEN-DIE FORGING, MOST ARE RATHER SIMPLE SOLIDS OR HOLLOWS REQUIRING CONSIDERABLE MACHINING TO ACHIEVE FINAL SHAPE. SCENE 24. tape 488, 00:03:27-00:03:35 open-die forgings using simple flat die tape 483, 10:00:40-10:00:50 static, v-shaped die tape 484, 15:04:42-15:05:08 zoom out, mandrel being used in open-die forging CG, SUPER: Saddles Blocks Rings Mandrels Punches FORGINGS ARE PRODUCED USING SIMPLE FLAT..., V-SHAPED..., OR SEMI-ROUND DIES. VARIOUS ACCESSORY TOOLS ARE ALSO USED, INCLUDING SADDLES..., BLOCKS..., RINGS..., MANDRELS..., AND PUNCHES. SCENE 25. tape 478, 05:20:52-05:21:09 zoom out, c.u. die lengthening ingot during forging TO WITHSTAND FORGING TEMPERATURES, ABRASION AND IMPACT, DIES AND ACCESSORY TOOLS ARE USUALLY MADE

6 OF HOT-WORK TOOL STEELS OR MEDIUM-CARBON ALLOY STEELS. SCENE 26. tape 484, 15:16:04-15:16:18 piercing operation LUBRICANTS ARE NOT ALWAYS USED IN OPEN-DIE FORGING. WHEN THEY ARE REQUIRED, THESE LUBRICANTS ARE USUALLY GRAPHITE DISPERSED IN OIL OR WATER. SCENE 27. tape 488, 00:10:44-00:11:13 handling equipment used in open die forging CG, SUPER: Workpiece transfer from heating furnace to forging machine Manipulation during forging Off-loading of finished forgings tape 481, 13:04:53-13:04:59 manually handled tongs tape 478, 05:29:08-05:29:15 floor vehicles with heavy-duty tongs tape 479, 06:09:49-06:09:55 cranes with lifting devices tape 478, 05:10:16-05:10:24 rotators to rotate the workpiece about its central axis HANDLING EQUIPMENT IS USED FOR VARIOUS PURPOSES IN OPEN-DIE FORGING, SUCH AS WORKPIECE TRANSFER FROM HEATING FURNACE TO FORGING MACHINE, MANIPULATION DURING FORGING, AND OFF-LOADING OF FINISHED FORGINGS THIS HANDLING EQUIPMENT INCLUDES: MANUALLY HANDLED TONGS, FLOOR VEHICLES WITH HEAVY-DUTY TONGS, CRANES WITH LIFTING DEVICES, AND ROTATORS TO ROTATE THE WORKPIECE ABOUT ITS CENTRAL AXIS. SCENE 28. tape 488, 00:17:35-00:17:46 manipulator being governed by controller WITH MANIPULATORS, THE SEQUENCE OF FORGING OPERATIONS CAN BE CONTROLLED BY THE MACHINE OPERATOR OR PROGRAMMED FOR AUTOMATIC OPERATION. SCENE 29. tape 488, 00:19:16-00:19:40 open-die forging of multidiameter shaft CG, SUPER: Rings Spindles Gears Wheels Tools Dies COMMON APPLICATIONS FOR THE OPEN-DIE FORGINGS INCLUDE MULTI-DIAMETER OR ECCENTRIC SHAFTS, AS WELL AS RINGS, SPINDLES, GEARS, WHEELS, TOOLS AND DIES, AND MANY OTHER PARTS.

7 --- FADE TO BLACK --- SCENE 30. Impression-Die Forging white text on black SCENE 31. tape 492, 21:11:18-21:11:29 impression-die forging operation IMPRESSION-DIE FORGING, ALSO CALLED CLOSED-DIE FORGING, IS THE DEFORMATION OF METAL AT FORGING TEMPERATURE WITHIN ONE OR MORE DIE IMPRESSIONS, OR CAVITIES. IT IS PERFORMED BOTH IN PRESSES AND HAMMERS. SCENE 32. tape 481, 13:26:16-13:26:30 impression-die, round workpiece, flattened and forged WORKPIECES MAY BE ROUND OR RECTANGULAR IN CROSS SECTION, OR FLAT DISKS, AND THE DIES ARE SOMETIMES INTEGRALLY HEATED TO MINIMIZE CHILLING AND COOLING OF THE WORKPIECE. SCENE 33. tape 481, 13:22:27-13:22:36 impression-die, simple shape, single stroke tape 481, 13:17:00-13:17:26 impression-die, sequential preforming FOR SIMPLE SHAPES, IMPRESSION-DIE FORGING CAN BE PERFORMED IN A SINGLE PRESS STROKE. MORE OFTEN, HOWEVER, SEVERAL STROKES OF DIFFERENT FORCE ARE USED WITH DIES HAVING SEVERAL IMPRESSIONS FOR SEQUENTIAL PREFORMING AND FINISH-FORGING OPERATIONS. SCENE 34. continue previous shot CG, SUPER: Edging tape 487, 00:00:50-00:00:55 ANI: edging CG, SUPER: Blocking tape 487, 00:00:55-00:01:00 ANI: blocking CG, SUPER: Finish-Forging tape 487, 00:01:00-00:01:05 ANI: finish-forging PREFORMING OPERATIONS MAY INCLUDE: EDGING, TO INCREASE THE WORKPIECE CROSS-SECTION; BLOCKING, TO REFINE THE SHAPE FOR FINISH-FORGING; AND FINISH-FORGING TO COMPLETE THE SHAPE.

8 SCENE 35. tape 487, 00:03:02-00:03:16 ANI: cutaway, impression-die with land and gutter, forging operation, workpiece red hot, flash cooling down forcing material into cavity impression CG, SUPER: Flash IN FINISH FORGING, THE BULK OF THE METAL IS FORCED INTO THE IMPRESSION WHILE A THIN LAYER, CALLED FLASH, FLOWS OUT BETWEEN THE DIES AT THE PARTING PLANE, SURROUNDING THE FORGING. SCENE 36. tape 487, 00:03:50-00:04:02 GRAPHIC: c.u. of cutaway, emphasizing the land and gutter add arrow to show land and bulbous region at end of land tape 476, 03:09:26-03:09:49 c.u. part being finished-forged, emphasize flash around part tape 476, 03:03:05-03:03:15 flash removed in trimming die FLASH COMPRISES A FLAT REGION, CALLED THE LAND, AND SOMETIMES A BULBOUS REGION AT THE END OF THE LAND CREATED BY A GUTTER IN THE UPPER DIE. THE THIN FLASH COOLS RAPIDLY, INCREASING PRESSURE WITHIN THE IMPRESSION, WHICH ASSISTS METAL FLOW IN IMPRESSION DETAILS. ONCE FINISH FORGING IS COMPLETE, THE FLASH IS REMOVED EITHER MANUALLY OR WITH TRIMMING DIES. SCENE 37. tape 363, 02:02:31-02:02:47 flashless impression-die forging FLASHLESS IMPRESSION-DIE FORGINGS ALSO CAN BE MADE, REDUCING METAL CONSUMPTION. HOWEVER, THE SIZE AND SHAPE OF THE WORKPIECE MUST BE MORE ACCURATELY CONTROLLED TO ENSURE THAT ALL THE METAL FLOWS INTO THE IMPRESSION. SCENE 38. tape 474, 01:04:09-01:04:28 wide, impression-die gear being forged, match action to next shot tape 474, 01:03:41-01:03:55 c.u. impression-die gear being IMPRESSION-DIE FORGING REQUIRES ACCURATE CONTROL OF WORKPIECE TEMPERATURE, DIE ALIGNMENT AND

9 forged WORKPIECE VOLUME TO ENSURE FILLING ALL PART DETAILS IN THE IMPRESSION WITHOUT GENERATING EXCESSIVE PRESSURE ON THE EQUIPMENT. SCENE 39. tape 476, 03:08:27-03:08:50 emphasize lubricants in impression-die forging LUBRICANTS, MOST OFTEN GRAPHITE IN OIL OR WATER, ARE IN COMMONLY USED FOR IMPRESSION-DIE FORGING. SCENE 40. continue previous shot CG, SUPER: Minimize friction Minimize abrasion Minimize heat loss Enhance metal flow Permits release of forging from dies LUBRICANTS MINIMIZE FRICTION, ABRASION AND HEAT LOSS, THEY ENHANCE METAL FLOW, AND PERMIT RELEASE OF THE FORGING FROM THE DIES. SCENE 41. tape 492, 21:02:11-21:02:30 zoom out, complex impression-die forging operation IMPRESSION-DIE FORGING IS TYPICALLY USED TO PRODUCE MORE COMPLEX SHAPES THAN OPEN-DIE FORGING. AND THE FORGINGS ARE MORE PRECISE AND MUCH CLOSER TO NET SHAPE, OFTEN REDUCING THE NEED FOR SUBSEQUENT MACHINING. SCENE 42. tape 481, 13:16:17-13:16:42 impression-die forging operation tape 492, 21:04:25-21:04:42 complex impression-die forging operation COMPLEXITY OF SHAPE THAT CAN BE FORGED DEPENDS ON THE FORGEABILITY OF THE WORKPIECE METAL OR ALLOY. LONG, THIN RIBS AND WEBS ARE DIFFICULT TO IMPART BECAUSE OF THE LARGE VOLUME OF METAL THAT HAS TO FLOW IN A CONFINED REGION. SCENE 43. tape 476, 03:00:34-03:00:54 high quantity impression-die forging tape 490, 02:19:46-02:20:12 engine connecting rods forging DIE COST FOR IMPRESSION-DIE FORGING IS GREATER THAN FOR OPEN-DIE FORGING, SO THE PROCESS IS USUALLY LIMITED TO HIGH-QUANTITY PRODUCTION.

10 HOWEVER, REDUCED MACHINING MAY OFFSET HIGHER DIE COST EVEN FOR LIMITED PRODUCTION. ALSO, THE METALLURGICAL STRUCTURE INDUCED BY IMPRESSION-DIE FORGING MAY BE MANDATORY FOR REQUIRED PART PERFORMANCE. SCENE 44. tape 490, 02:19:10-02:19:25 engine connecting rods on conveyor tape 483, 11:04:09-11:04:30 aircraft-engine part being forged tape 5, 00:03:12-00:03:20 large impression-die forging tape 474, 01:09:06-01:09:20 small impression-die forging AUTOMOBILE ENGINE CONNECTING RODS EXEMPLIFY PARTS REQUIRED IN HIGH QUANTITIES. AIRCRAFT BULKHEADS AND AIRCRAFT-ENGINE PARTS ARE MADE IN MUCH FEWER QUANTITIES, YET ARE ECONOMICALLY JUSTIFIED. ALTHOUGH VERY LARGE PARTS, MEASURED IN THOUSANDS OF KILOGRAMS, HAVE BEEN MADE, MOST IMPRESSION-DIE FORGINGS ARE SMALL TO MODERATE IN SIZE. --- FADE TO BLACK --- SCENE 45. Related Forging Processes white text centered on black SCENE 46. tape 478, 05:09:54-05:10:05 open-die forging tape 481, 13:18:06-13:18:17 impression-die forging tape 468, 00:09:00-00:10:00 blue background CG: Seamless Ring Rolling Hot-Die Forging Isothermal Forging OPEN-DIE..., AND IMPRESSION-DIE FORGING ENCOMPASS A WIDE VARIETY OF SPECIFIC PROCESSES, WHICH INCLUDE: SEAMLESS RING ROLLING, HOT-DIE FORGING, AND ISOTHERMAL FORGING. SCENE 47. CG, SUPER: Seamless Ring Rolling tape 484, 15:23:36-15:23:55 zoom out, seamless ring rolling SEAMLESS RING ROLLING IS THE CIRCUMFERENTIAL EXPANSION AND CROSS SECTION REDUCTION OF A CENTRALLY PIERCED DISK-SHAPED WORKPIECE ON A RING-

11 ROLLING MACHINE. SCENE 48. tape 485, 11:16:39-11:17:05 seamless ring rolling with exterior contour A VARIETY OF CROSS-SECTIONAL PROFILES CAN BE PRODUCED, SUCH AS SQUARE, RECTANGULAR, AND SECTIONS WITH INTERIOR AND EXTERIOR CONTOURS. SCENE 49. tape 484, 15:21:40-15:22:44 wide, seamless ring rolling THE WORKPIECE IS PLACED BETWEEN AN UNDRIVEN ROLL, OR MANDREL, AND A DRIVEN OUTER ROLL. THE OUTER ROLL ROTATES THE WORKPIECE, WHICH, BY FRICTION, ROTATES THE MANDREL. AS THE GAP BETWEEN THE DRIVEN ROLL AND MANDREL DECREASES, THE WORKPIECE CROSS- SECTION THINS AND THE RING DIAMETER EXPANDS. SCENE 50. continue previous shot THE CROSS-SECTION PROFILE IS CONTROLLED BY THE SHAPE OF THE MANDREL AND THE DRIVEN ROLL. SCENE 51. continue previous shot CROSS-SECTION HEIGHT IS CONTROLLED BY THE DRIVEN ROLL OR BY A CONICAL AXIAL ROLL OR ROLLS ON THE OPPOSITE SIDE. SCENE 52. tape 485, 11:15:52-11:16:04 wide, small seamless ring rolling tape 484, 15:22:51-15:23:02 wide, large seamless ring rolling MOST RING-ROLLED FORGINGS RANGE FROM 20 CENTIMETERS TO OVER ONE METER IN DIAMETER WITH CROSS-SECTIONS BETWEEN 5 TO 20 CENTIMETERS HIGH AND 1 TO 5 CENTIMETERS THICK. HOWEVER, MUCH LARGER AND SMALLER ONES CAN BE PRODUCED. SCENE 53. tape 485, 11:14:21-11:14:33 ring rolled forgings on conveyor

12 CG, SUPER: Gear Blanks Bearing Races Valve Bodies Wheels Turbine Components RING-ROLL FORGING IS USED TO PRODUCE GEAR BLANKS, BEARING RACES, VALVE BODIES, WHEELS, TURBINE COMPONENTS AND MANY OTHER PARTS. --- TOUCH BLACK --- SCENE 54. CG, SUPER: Hot-Die Forging tape 363, 02:05:18-02:05:23 hot-die forging CG, SUPER: Isothermal Forging tape 363, 02:00:18-02:00:43 ingot fed to die on isothermal press HOT-DIE FORGING, AND ISOTHERMAL FORGING BOTH REFER TO THE USE OF HEATED DIES IN FORGING A WORKPIECE THAT IS HEATED TO ITS FORGING-TEMPERATURE RANGE. SCENE 55. continue previous shot tape 363, 02:05:25-02:05:41 2 shots, hot-die forging tape 363, 02:00:57-02:01:34 3 shots, dies opening and forging removed from isothermal press, part cooling THE DISTINCTION BETWEEN HOT-DIE FORGING AND ISOTHERMAL FORGING IS A MATTER OF DIE TEMPERATURE. IN CONVENTIONAL HOT-DIE FORGING, THE DIES ARE MAINTAINED AT A TEMPERATURE LESS THAN THAT OF THE WORKPIECE S FORGING-TEMPERATURE RANGE. IN ISOTHERMAL FORGING, THEY ARE MAINTAINED AT THE WORKPIECES FORGING TEMPERATURE RANGE. SCENE 56. continue previous shot USE OF HEATED DIES IS IMPORTANT IN FORGING CONDUCTIVE METALS, SUCH AS ALUMINUM AND HIGH- COPPER ALLOYS, AS WELL AS ALLOYS HAVING A NARROW FORGING-TEMPERATURE RANGE, SUCH AS CERTAIN TITANIUM ALLOYS AND NICKEL SUPERALLOYS. SCENE 57. continue previous shot tape 363, 02:04:01-02:04:22 4 shot sequence, hot die forging of precision part, unloading of part USING HEATED DIES REDUCES OR ELIMINATES CHILLING OF THE WORKPIECE. THIS ALLOWS FORGING MORE COMPLEX SHAPES, FORGING CLOSER TO NET SHAPE, AND FORGING

13 TO GREATER PRECISION THAN IN CONVENTIONAL FORGING. SCENE 58. continue previous shot PARTS FORGED TO GREATER PRECISION THAN BY CONVENTIONAL FORGING ARE CALLED PRECISION FORGINGS. SCENE 59. tape 363, 02:03:40-02:03:57 2 shots, hot die forged part being inspected for tolerances FOR ALUMINUM ALLOYS AND TITANIUM ALLOYS, PRECISION FORGING CAN REDUCE DRAFT, OR TAPER, OF SIDE WALLS AND INTERNAL PROJECTIONS. RIB AND WEB FEATURES CAN ALSO BE THINNER. IN ADDITION, PRECISION FORGING CAN GENERATE A SMOOTH SURFACE FINISH. --- FADE TO BLACK --- SCENE 60. Forging Automation white text centered on black SCENE 61. tape 363, 02:13:53-02:14:09 forging mold building on computer screen THE COMPUTER HAS HAD A MARKED EFFECT IN ENHANCING FORGING TECHNOLOGY. SCENE 62. tape 477, 04:04:45-04:04:56 computer screen, mold tape 363, 02:05:44-02:05:49 drawing being generated WITH COMPUTER PROGRAMS, DIES CAN BE DESIGNED MORE EFFICIENTLY FOR SPECIFIC PARTS OR FAMILIES OF PARTS AND DRAWINGS GENERATED ON DEMAND. SCENE 63. tape 363, 02:14:18-02:14:28 computer based forging sequence OPTIMUM FORGING SEQUENCES BASED ON PART GEOMETRY ALSO CAN BE ESTABLISHED AND FORGING REQUIREMENTS DETERMINED FOR PRESS SELECTION.

14 SCENE 64. tape 480, 12:26:39-12:26:55 automated shop floor forging operation COMPUTER-CONTROLLED FORGING SYSTEMS CAN PROVIDE VIRTUALLY FULL AUTOMATION. THEY CAN MARKEDLY INCREASE PRODUCTION RATES, REDUCE REJECTS, CONSERVE METAL AND REDUCE LABOR COSTS. SCENE 65. tape 490, 02:05:43-02:06:13 dolly, automated forging operation CG, ROLL: Billet or bar loading Furnace heating Hot shearing to workpiece length Preforming Lubrication Single or multiple die forging operations Trimming Straightening Unloading the forging Die changing AUTOMATED OPERATIONS CAN INCLUDE BILLET OR BAR LOADING, FURNACE HEATING, HOT SHEARING TO WORKPIECE LENGTH, PREFORMING, LUBRICATION, SINGLE OR MULTIPLE DIE-FORGING OPERATIONS, TRIMMING, STRAIGHTENING, UNLOADING THE FORGING AND DIE CHANGING. --- FADE TO BLACK --- SCENE 66. CG: Review white text on black tape 63, 12:00:15-12:03:49 review music MUSIC UP AND UNDER LET S REVIEW THE MATERIAL CONTAINED IN THIS VIDEOTAPE. SCENE 67. tape 480, 12:09:20-12:09:29 forging of part tape 480, 12:14:23-12:14:33 forging in hammer tape 485, 11:05:40-11:05:48 forging in press FORGING IS THE CONTROLLED DEFORMATION OF METAL INTO SPECIFIC SHAPES BY COMPRESSIVE FORCES APPLIED THROUGH TOOLS AND DIES DRIVEN BY HAMMERS..., AND PRESSES. SCENE 68. tape 485, 11:07:18-11:07:36 forging of part CG, SUPER: Forgeability Metal s/alloy s Composition Crystal Structure ALL METALS AND ALLOYS ARE FORGEABLE. FORGEABILITY, THE EXTENT TO WHICH THEY CAN BE DEFORMED, DEPENDS

15 Mechanical Properties ON THEIR COMPOSITION, CRYSTAL STRUCTURE AND MECHANICAL PROPERTIES. SCENE 69. tape 484, 15:02:39-15:02:53 zoom in, open die forging operation, reducing cast ingot into wrought mill form tape 484, 15:14:19-15:14:35 ring rolling operation on wrought mill form FORGING REDUCES THE CROSS-SECTION, IMPROVES THE METALLURGICAL MICROSTRUCTURE, PROVIDES DIRECTIONAL GRAIN FLOW AND ELIMINATES POROSITY OF CAST INGOT. IN FORGING PARTS FROM THESE WROUGHT MILL FORMS, FORGING CAN FURTHER REFINE MICROSTRUCTURE AND GRAIN FLOW. SCENE 70. CG, SUPER: Open-Die Forging tape 488, 00:02:58-00:03:08 open-die forging CG, SUPER: Impression-Die Forging tape 481, 13:17:22-13:17:26 impression-die forging THE TWO PRINCIPAL TYPES OF FORGING ARE OPEN-DIE FORGING..., AND IMPRESSION-DIE FORGING. SCENE 71. tape 484, 15:04:07-15:04:22 open-die forging of ingot OPEN-DIE FORGING IS DEFORMATION OF THE WORKPIECE BETWEEN FLAT OR SHAPED DIES WITHOUT COMPLETELY RESTRICTING METAL FLOW. SCENE 72. tape 488, 00:08:00-00:08:28 open-die forging of large part OPEN-DIE FORGING IS USED IN THE PRODUCTION OF WROUGHT MILL FORMS AND TO PRODUCE PARTS OF SIMPLE SHAPE. SCENE 73. tape 492, 21:04:25-21:04:43 complex impression-die forging operation IMPRESSION-DIE FORGING, ALSO CALLED CLOSED-DIE FORGING, IS THE DEFORMATION OF METAL WITHIN ONE OR MORE DIE IMPRESSIONS, OR CAVITIES. IT IS USED TO FORM PARTS, WHICH CAN BE QUITE COMPLEX IN SHAPE.

16 SCENE 74. tape 478, 05:09:54-05:10:05 open-die forging tape 481, 13:18:06-13:18:17 impression-die forging tape 468, 00:09:00-00:10:00 blue background CG: Seamless Ring Rolling Hot-Die Forging Isothermal Forging OPEN-DIE..., AND IMPRESSION-DIE FORGING ENCOMPASS MANY SPECIFIC PROCESSES, INCLUDING: SEAMLESS RING ROLLING, HOT DIE FORGING, AND ISOTHERMAL FORGING. SCENE 75. CG, SUPER: Seamless Ring Rolling tape 484, 15:23:36-15:23:55 zoom out, seamless ring rolling SEAMLESS RING ROLLING IS THE CIRCUMFERENTIAL EXPANSION AND CROSS-SECTION REDUCTION OF A CENTRALLY PIERCED DISK-SHAPED WORKPIECE. IT IS USED TO MAKE GEAR BLANKS, WHEELS, AND MANY OTHER PARTS. SCENE 76. CG, SUPER: Hot-Die Forging tape 363, 02:05:18-02:05:23 hot-die forging CG, SUPER: Isothermal Forging tape 363, 02:00:18-02:00:43 ingot fed to die on isothermal press HOT-DIE FORGING..., AND ISOTHERMAL FORGING REFER TO THE USE OF INTEGRALLY HEATED DIES IN FORGING A WORKPIECE HEATED TO ITS FORGING-TEMPERATURE RANGE. SCENE 77. tape 363, 02:05:25-02:05:41 2 shots, hot-die forging tape 363, 02:00:57-02:01:34 3 shots, dies opening and forging removed from isothermal press, part cooling IN MOST HOT FORGING, DIES ARE MAINTAINED AT A LOWER TEMPERATURE THAN THE WORKPIECE. IN ISOTHERMAL FORGING, THE DIES ARE KEPT AT THE FORGING-TEMPERATURE RANGE OF THE WORKPIECE. SCENE 78. tape 477, 04:04:45-04:04:56 computer screen, mold tape 480, 12:26:39-12:26:55 automated shop floor forging operation THE COMPUTER HAS HAD A MARKED EFFECT IN ENHANCING FORGING TECHNOLOGY, FROM DIE DESIGN AND ANALYSIS TO VIRTUALLY FULL COMPUTER-CONTROLLED FORGING

17 AUTOMATION. --- FADE TO BLACK --- SCENE 79. CG, ROLL: credits white text on black, fade up mid-screen Produced By: The Society Of Manufacturing Engineers Executive Producer: Steven Bollinger Producer/Director: Jerome T. Cook Written By: John A. Vaccari Graphics By: Dennis Summers Equipment Access Provided By: American Axle and Manufacturing, Detroit Forge American Axle and Manufacturing, Tonawanda, NY Brenco Incorporated Composite Forge Durgam Industries, LTD. Federal Forge Henry Ford Museum & Greenfield Village Pioneer Forge Teledyne Portland Forge Ringmasters Manufacturing LLC Video Footage Provided By: Ladish Co. Masco Tech Sandvik Coromant Company

18 Scot Forge Technical Assistance Provided By: Charles Hageman, Forging Industry Association Production Assistance Provided By: Julie Moyer Doug Trevethan Lance Rosol Video Editing: Communicore Visual Communications SCENE 80. CG: disclaimer white text centered on black Some machinery in this program had safety equipment removed to allow better recording of certain processes. Always read the safety information provided in the manufacturers manual before operating any machine. SCENE 81. tape 40, 01:00:00-01:00:12 SME logo