Hot Forming. Kalpakjian

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1 Hot Forming Kalpakjian

2 Hot Working: Forging Open Die Forging Paul Berenson, T.Green, WIT

3 Forging: Heat Loss Metal near die surfaces are coolest, flow less

4

5 Temperature in Metal Forming For any metal, K and n in the flow curve depend on temperature Both strength and strain hardening are reduced at higher temperatures In addition, ductility is increased at higher temperatures Tm is melting temperature +273

6 Comparison Cold Working Hot Working Carried below recrystallization temp. Carried above recrystallization temp. Hardening is not eliminated, rather Strain hardening is completely accompanied by strain hardening eliminated Elongation, area reduction, ductility Ductility, elongation, area reduction and impact strength are reduced and impact strength are increased Crystallization does not occur Crystallization occurs again Uniformity of material is lost and Grain refinement occurs properties are greatly affected Chances of crack propagation is Cracks and defects like blow holes, more cavities are welded Increases ultimate tensile strength, Does not affect ultimate tensile yield point, hardness, fatigue strength, yield point, hardness, strength fatigue strength 6

7 Resistance to corrosion decreases due to presence of residual stresses Internal and residual stresses are produced Load and energy requirements are high Less tool wear Less costly No oxidation of metal occurs No metal loss Surface decarbonization of steel does not occur Good surface finish High dimensional accurcy Easy to control dimensions within tolerance limits Material handling is easy Resistance to corrosion is not affected Internal and residual stresses are not produced Load and energy requirements are low High tool wear High cost operation High scaling and oxidation occurs High metal loss Surface decarbonization of steel occurs Surface finish is not good low dimensional accurcy Difficult to control dimensions within tolerance limits Material handling is difficult 7

8 FORGING Forging is term applied to a family of processes where deformation is induced by localized compressive forces. The equipment can be manual or power hammers, presses, or special forging machines. The hot forging done above the recrystailization temperature. The cold forging done below the recrystailization temperature.

9 FORGING The forging material may be subjected to: 1-Drawn out to increase its length and decrease its cross section, 2-Upset to decrease the length and increase the cross section, 3-Squeezed in closed impression dies to produce multidirectional flow.

10 Different types of Forging processes Open Die Forgings or Hand forgings. Impression Die Forgings or Precision Forgings or closed die forging. Upset Forgings 1- Open Die Forgings or Hand forgings. In this process the forgings are made with the help of repeated blows in an open die. Here the operator manipulates the work piece in the die during the blow process, similar to the traditional manufacturing process used by a blacksmith.

11 Open Die Forgings or Hand forgings Open-die forging is the same type of forging done by blacksmith. Metal is first heated to proper temperature by gas, oil, or electric furnaces. Impact delivered by some type of hammer like pneumatic hammer or board hammer.

12 Open die forging Blacksmiths use this process to reduce the thickness of bars by hammering the part on an anvil. Reduction in thickness is accompanied by barreling, as in Fig. 14.3c. (b) Reducing the diameter of a bar by open-die forging; note the movements of the dies and the workpiece. (c) The thickness of a ring being reduced by open-die forging.

13 Stages in Open-Die Forging (a) forge hot billet to max diameter (b) fuller: tool to mark step-locations (c) forge right side (d) reverse part, forge left side (e) finish (dimension control) [source:

14 Open-Die Drop-Hammer Forging Steam or air hammers(pneumatic hammers) use pressure to : give higher striking velocities, more control of striking force, easier automation, the ability to shape pieces up to several tons.

15 pneumatic hammer

16 Open-Die Drop-Hammer Forging Open-die forging is usually employed to pre-shape metal for further manufacturing operations for example consider such massive parts turbine rotors and generator shafts which may be 70 ft in length and up to 3 ft in diameter. Open-die forging is used to minimize the amount of subsequent machining. Open die forging is considered as a primary forging process.

17 2-Impression-Die Drop-Hammer Forging Impression Die Forgings or Precision Forgings These forgings are the refined form of blocker forgings. The finished metal part much more identical to the die impression. Impression-die or closed-die forging overcomes these difficulties of obtaining the final shape by using shaped dies to control the flow of metal. Consist of set of dies, one half of which attaches to hammer and other half to anvil. Impression die may be flash and flash less

18 Impression-Die Drop-Hammer Forging Heated metal is positioned in lower cavity and struck one or more blows by upper die. Hammering causes the metal to flow to completely fill die cavity. Excess metal is squeezed out around the periphery of the cavity to form a flash. When final forging is completed, flash is trimmed off by trimming die.

19 Stages in Impression-die (Closed-Die) Forging Stages in Impression-die (Closed-Die) Forging( flash) [source:kalpakjian & Schmid]

20 Stages in Impression-die (Closed-Die) Forging(flash)

21

22 Impression-Die Forging( flash shape) (a) through (c) Stages in impression-die forging of a solid round billet. Note the formation of flash, which is excess metal that is subsequently trimmed off (d) Standard terminology for various features of a forging die.

23 Flash less forging

24 Impression-Die Drop-Hammer Forging Final shape and size are set by additional forging in the final or finisher impression The shape of the various cavities forces the metal to flow in the desired direction. After forging, the flash is trimmed The part is quenched to room temperature.

25 Impression-Die Drop-Hammer Forging Advantages 1- complicated shapes 2- accurate dimensions. 3- better surface properties. 4- can be used in mass production scale. 5- mechanical properties is achieved by thermal treatment. 6- reduce scraps by using flash.

26 Trimming Flash After Forging Trimming flash from a forged part. Note that the thin material at the center is removed by punching.

27 Press Forging Hydraulic presses with capacities up to 50,000 tons (445 MN) are used. Press forgings have higher dimensional accuracy and can often be completed in a single closing of dies and the process can be readily automated.

28 10000T ton

29 Upset Forging Upsetting or Upset Forging is the simplest case of open-die forging involving compression of a workpiece between two flat dies. Upset forging reduces the height of the workpiece but increases its cross-sectional area. We will consider upsetting of a round billet. Under ideal conditions where there is no friction between the work piece and the dies, the billet deforms homogeneously (the cylindrical shape of the billet remains cylindrical throughout the process). But in practical conditions the billet tends to barrel since there is some friction. 29

30 Homogeneous upsetting of a cylindrical billet (without friction) Homogeneous Practical upsetting of a cylindrical of a cylindrical billet (with friction billet &(with barreling) friction & barreling) 30

31 Terminology In homogeneous upsetting / no friction: TrueStrain, ln h o = starting height of workpiece (before deformation) h = instantaneous height of the work piece (at an intermediate press stroke) TrueStress F A h h o (1) (2) F = instantaneous upsetting force A = instantaneous cross sectional area of the workpiece 31

32 In homogeneous upsetting: Terminology Upsetting Force F Y f A (3) Y f flow stress n K (4) K = strength coefficient, n = strain hardening coefficient F increases with deformation (press stroke) since Y f and A both increase with deformation and strain (Eqs. (1), (3) & (4)) 32

33 Terminology Practical Upsetting of a cylindrical workpiece (with friction & barreling): F K Y A (5) f f Forging Shape Factor K f 0.4 D 1 (6) h Where = coefficient of friction ( ) D = instantaneous workpiece diameter, mm (in), h = instantaneous workpiece height, mm (in) 33

34 Specimen before and after the compression: h o h 1 D o D1 (avg) V billet D 2 o h0 volume 4 D 1 (average) can be calculated from volume constancy, i.e., D 1 V.4 h1 34

35 Specimen before and after the compression: Original Specimen Barreled Specimen after compression 35

36 Comparison of cold and hot forging: Original steel specimen Steel specimen after cold forging (5 steps/hits) Steel specimen after hot forging 36

37 Swaging Swaging generally involves the hammering of a rod or tube to reduce its diameter where the die itself acts as the hammer Term swaging is also applied to processes where material is forced into a confining die to reduce its diameter.

38 Swaging 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. Source: Courtesy of J. Richard Industries.

39 Closed-die forging process Coining Closed-die forging process Used for minting coins, medallions, & jewelry Lubricants can not be used in coining Can be used to improve surface finish

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