Forging

02/02/2014 die application 1
Application of Dies
The art of die design is to predict properly
irregular or regular die shape which will allow
metal to reshape into desired (regular) to the
different profile of shape.
Forms metal to the desired shape by plastic
deformation
A chip less process that produces required
shape

Types of Forging Dies----
Open die forging - work is compressed
between two flat dies, allowing metal to flow
laterally with minimum constraint
Impression die forging - die contains
cavity or impression that is imparted to work
part
Metal flow is constrained so that a flash is
created
Fleshless forging - work part is completely
constrained in die
No excess flash is created
Open-Die Forging
Compression of workpart between two flat dies
Deformation operation reduces height and increases
diameter of work
Common names: upsetting or upset forging
Open-Die Forging with No
Friction
If no friction occurs between work and die surfaces,
then homogeneous deformation occurs, so that
radial flow is uniform throughout workpart height and
true strain is given by:

h
h
o
ln = c
Open-Die Forging with Friction
Friction between work and die surfaces constrains
lateral flow of work, resulting in barreling effect
In hot open-die forging, effect is even more
pronounced due to heat transfer at and near die
surfaces, which cools the metal and increases its
resistance to deformation.

Impression Die Forging
Flash is formed by metal that flows beyond die cavity into
small gap between die plates
Flash serves an important function:
As flash forms, friction resists continued metal flow into gap,
constraining material to help fill die cavity
In hot forging, metal flow is further restricted by cooling against
die plates
Advantages and Limitations
Impression
Advantages of impression-die forging compared
to machining from solid stock:
Higher production rates
Less waste of metal
Greater strength
Favorable grain orientation in the metal
Limitations:
Not capable of close tolerances
Machining often required to achieve accuracies and
features needed
Flashless Forging
Starting workpart volume
must equal die cavity
volume to very close
tolerance
Process control more
demanding than
impression-die forging
Best suited for geometries
that are simple and
symmetrical
Process often classified as
precision forging
Upsetting and Heading
Forging process used to form heads on nails,
bolts, and similar hardware products
More parts produced by upsetting than any
other forging operation
Performed cold, warm, or hot on machines
called headers or formers
Wire or bar stock is fed into machine, end is
headed, then piece is cut to length
For bolts and screws, thread rolling is then
used to form threads
Upset forging cycle to form a head on a bolt or similar
hardware item consists of: (1) wire stock fed to the stop, (2)
gripping dies close on the stock and stop is retracted, (3)
punch moves forward, (4) bottoms to form the head.
Upset Forging
Examples of heading operations: (a) heading a nail using
open dies, (b) round head formed by punch, (c) and (d) two
common head styles for screws formed by die, (e) carriage
bolt head formed by punch and die.
Heading (Upset Forging)
Forging Calculations
Just at the yield point assumes the strain, = 0.002
The flow stress at any value of strain:
Y
f
= K
n

The force required for upset forging:
F = K
f
Y
f
A
f
- as strain increases A increases
- use conservation of volume
Where K
f
= 1 + is the forging shape factor

coefficient of friction (at Die-work interface)
D workpart diameter (or contact length with die)
h workpart height
A cross-sectional area (in contact with die)
f
f
h
D 4 . 0
Wire and Bar Drawing
Cross-section of a bar, rod, or wire is reduced
by pulling it through a die opening
Similar to extrusion except work is pulled
through the die in drawing.
Both tensile and compressive stress deform the
metal as it passes through die opening.
02/02/2014 die application
15
16
Features of a Draw Die
Entry region - funnels lubricant into the die to prevent
scoring of work and die
Approach - cone-shaped region where drawing occurs
Bearing surface - determines final stock size
Back relief - exit zone - provided with a back relief angle
(half-angle) of about 30

Continuous Wire Drawing
Continuous drawing machines consisting of multiple draw dies
(typically 4 to 12) separated by accumulating drums
Each drum (or capstan) provides proper force to draw wire stock
through its upstream die
Each die provides only a small portion of the overall reduction
Annealing is sometimes required between dies to relieve work
hardening
Deep Drawing
Basic drawing operation a cup-shape part
D
p
D
b
D
p
F
F
h F
h
c c
Detail Steps of Drawing
Initial contact
Bending
Straightening
Friction and compression
Final shape
Analysis of Drawing
Measure of Drawing
Drawing ratio: feasible if DR<2

Reduction feasible if r<0.5
Crude measures of the severity of a deep drawing
operation
Drawing Forces:

Holding Force:
p
b
D
D
DR =
b
p b
D
D D
r

=
( )
|
|
.
|
\
|
= 7 . 0
p
b
p
D
D
TS t D F t
( ) | |
2
2
2 2 . 2 015 . 0
d p b h
R t D D Y F + + = t
Quiz
22
1. State that the art of forging with their type and
application.
2. State that the differences and similarities
between Flash and flash less forging
process.
3. Explain the following phrase based on the
production process and application concept.
Die
Wire drawing
Deep drawing

Forging

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02/02/2014 die application 1

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