Training on Forging technologyBasics

1. Forging deals with solid flow of material2. Two typesA/ Open Die forgingB/ Closed die forging

Open die forging A/ Big forgingsB/ Small qtyC/shorter development time

Closed die forgingA/high volumeB/Accurate profileC/Lower cost

Types of forging

1. Cold forging2. Hot forging3. Warm forging

Other classification1. hammer forging2. Press forging3. Upsetter forging4. Ring rolling 5. Orbital forging

1. Round forging2. Symmetrical forging3. Asymmetrical 4. Extrusion5 . Upset

Advantages of forging process

1. High strength2. High repeatability3. High productivity4. Surface finish5. Minimum machining

operations6. Material optimization

Classification of forging equipment

1. Hammer2. Press3. Up setter4. Others like orbital, swaging , rolling etc.

Hammers type

1. Steam/Air Hammer2. Spring hammer3. Drop hammer4. Counterblow hammer5. Friction board hammers6. Pneumatic hammers7. Hydraulic hammers

Presses 1. Mechanical2. Screw presses3. Hydraulic press

Up setter1. Horizontal2. Vertical3. Electric up setter4. Hatebur machines with transfer lines5. Rotary swages6. Chase rollers

Fundamental of Hammer

1. Lift by air/steam or Mechanical lift2. Drop by gravity or pressure3. Principle of impact

Fundamental of Press

1. Lifted mechanically or hydraulically2. Drop mechanically not by gravity3. Principle of squeezing pressure

Fundamental Up setter1. Same as presses2. Force applied on end of bars

Fundamental process of forging

1. Cut bar stockA/ shearing, B/ Hexa cutting2. Heating for hot forging/Warm forging and annealing for cold forging3. Descaling4. A..Upset / Blocking/Finishing(Gears) B.. Fuller, roll, block finish5. Trimming of excess flash6. Coining if required7. Fettling/ Grinding 8. Heat treat 9. Shot blast10. Inspection

                                                  

                      

                        

             

When to select hammer/ press / or upsetter

Hammer1. Low cost2. Quick development3. Low volume4. No additional subsidiary equipment necessary5. Larger draft angles upto 5-7Degree6. Complicated profiles

Press 1. Near net shape forging2. Large volume3. better surface finish4. Symmetrical forgings5. Deep extrusion6. Very low draft angles

Upsetter

1. Single ended and double ended forging2. Draftless forging3. Lower cost forging

Forging design fundamental

1. Input machining drawing2. Develop forging drawing3. Establish process4. Identify equipments5. Calculate raw material requirement6. Develop die drawing/Trim tool drgs7. Develop die template drgs and inspection template drgs8. Develop process plan9. Develop quality plan

Calculation of raw material1. Develop forging drawing as per IS3469 Tolerances2. Consider machining allowance, Mismatch allowancePunch eccentricity allowance, Scale pit alowance, Heat treat allowance, draft angles .3. Provide tolerance for mismatch, scaling , dimensions , general tolerances, Flatness, web shifts ,Weight tol,Radii, and other dimension, eccentricity, etc4. Maching allowance Upto 205=1.5Upto410=2.5 per surfaceUpto 610=4 mm persurface5. Calculate average weight of forging6. Add heating loss upto 2.5 % for conventional heating0.75% for Induction heating7.Add flash loss 1.2 to 1.25%8. Add 5% for cutting losses, end piece loss etc.For gears the gross weight of raw material blank is around 1.25%

Forging defects1.DimensionalA.MismatchB. Punch outC. Flash extention /BurrD. UnderfillE. LapF. Web shiftG. Scale pitH. WarpageI. Nick MarksJ. Seams/CracksK Thermal cracksL. Parting line cracksM. Punch marksetc

Selection of hammer

Forging wt Hammer energy MkgTo 1kg 13702.25kg 20604,5 kg 27407 kg 41009kg 546013kg 8200

Costing process

1/ Develop forging Drawing2/ Calculate Finish weight of forging3/ Calculate gross weight of forging4/ Calculate ConversionA.. Bar stock Shearing/ CuttingB.. Heating C.. Forging process costD..Heat treat ment costE.. Die costF.. Other costs

Slide 1: Training on Forging technology Basics Forging deals with solid flow of material Two types A/ Open Die forging B/ Closed die forging Open die forging A/ Big forgings B/ Small qty C/shorter development time Closed die forging A/high volume B/Accurate profile C/Lower cost

Slide 2: Types of forging Cold forging Hot forging Warm forging Other classification 1. hammer forging 2. Press forging 3. Upsetter forging 4. Ring rolling 5. Orbital forging Round forging 2. Symmetrical forging 3. Asymmetrical 4. Extrusion 5 . Upset

Slide 3: Advantages of forging process High strength High repeatability High productivity Surface finish Minimum machining operations Material optimization

Slide 4: Classification of forging equipment Hammer Press Up setter Others like orbital, swaging , rolling etc. Hammers type Steam/Air Hammer Spring hammer Drop hammer Counterblow hammer Friction board hammers Pneumatic hammers Hydraulic hammers

Slide 5: Presses Mechanical Screw presses Hydraulic press Up setter Horizontal Vertical Electric up setter Hatebur machines with transfer lines Rotary swages Chase rollers

Slide 6: Fundamental of Hammer Lift by air/steam or Mechanical lift Drop by gravity or pressure Principle of impact Fundamental of Press Lifted mechanically or hydraulically Drop mechanically not by gravity Principle of squeezing pressure Fundamental Up setter Same as presses Force applied on end of bars

Slide 7: Fundamental process of forging Cut bar stock A/ shearing, B/ Hexa cutting Heating for hot forging/Warm forging and annealing for cold forging Descaling A..Upset / Blocking/Finishing(Gears) B.. Fuller, roll, block finish Trimming of excess flash Coining if required Fettling/ Grinding Heat treat Shot blast Inspection

Slide 8: 

Slide 9: When to select hammer/ press / or upsetter Hammer Low cost Quick development Low volume No additional subsidiary equipment necessary Larger draft angles upto 5-7Degree Complicated profiles Press Near net shape forging Large volume better surface finish Symmetrical forgings Deep extrusion Very low draft angles

Slide 10: Upsetter Single ended and double ended forging Draftless forging Lower cost forging Forging design fundamental Input machining drawing Develop forging drawing Establish process Identify equipments Calculate raw material requirement Develop die drawing/Trim tool drgs Develop die template drgs and inspection template drgs Develop process plan Develop quality plan

Slide 11: Calculation of raw material Develop forging drawing as per IS3469 Tolerances Consider machining allowance, Mismatch allowance Punch eccentricity allowance, Scale pit alowance, Heat treat allowance, draft angles . 3. Provide tolerance for mismatch, scaling , dimensions , general tolerances, Flatness, web shifts ,Weight tol,Radii, and other dimension, eccentricity, etc 4. Maching allowance Upto 205=1.5 Upto410=2.5 per surface Upto 610=4 mm persurface 5. Calculate average weight of forging 6. Add heating loss upto 2.5 % for conventional heating0.75% for Induction heating 7.Add flash loss 1.2 to 1.25% 8. Add 5% for cutting losses, end piece loss etc. For gears the gross weight of raw material blank is around 1.25%

Slide 12: Forging defects 1.Dimensional A.Mismatch B. Punch out C. Flash extention /Burr D. Underfill E. Lap F. Web shift G. Scale pit H. Warpage I. Nick Marks J. Seams/Cracks K Thermal cracks L. Parting line cracks M. Punch marks etc

Slide 13: Selection of hammer Forging wt Hammer energy Mkg To 1kg 1370 2.25kg 2060 4,5 kg 2740 7 kg 4100 9kg 5460 13kg 8200

Slide 14: Costing process 1/ Develop forging Drawing 2/ Calculate Finish weight of forging 3/ Calculate gross weight of forging 4/ Calculate Conversion A.. Bar stock Shearing/ Cutting B.. Heating C.. Forging process cost D..Heat treat ment cost E.. Die cost F.. Other costs