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Forging hammer
In the heated metal forging process is overwritten with the steam forging machine between hand
tools or flat die. Forging hand made by the blacksmith is the oldest known way of forging. In the
process can not be obtained ii high accuracy and can not also be done on a complex workpiece.
Heavy wrought objects ranging from a few kilograms to 90 Mg
Figure 3. Diagram illustrating the sequence number of fitting and reduce the cross section of
100 x 100 mm billet into a round rod
forging overwriting
Differences forging hammer and forging die override located on the type used . Closed die
forging using the override , and the workpiece is formed due to impact or pressure , forcing
the hot metal plastic , and fill the form die . The principle works can be seen in Figure 5. In
this operation no metal flow in die burden caused by the barrage . To regulate the flow of
metal during the burden , this operation is divided into several steps . Every step of
changing the form of the work gradually , thus the metal flow can be set up to form the
workpiece .
Steel forging temperature for 1100 - 1250 C, copper and its alloys: 750-925 C,
magnesium: 370-450 C closed die forging with having weight ranging from a few grams to 10
Mg.
There are two kinds of forging machine override namely: steam hammer and hammer
gravity. In pembenturan steam hammer impact pressure caused by force hammer and die when
on the bottom die anyway. 6. In the picture looks hammer piston. To lift the used air or steam
hammer. Can be set high fall with the program, therefore, can produce a more uniform
workpiece. Hammer piston is made with a heavy hammer capacities ranging from 225 kg to
4500 kg. Hammer piston is widely used in industrial hand tools, scissors, spoons, forks, parts,
and aircraft parts.
Forging hammer impact as Figure 7 consists of two cylinders that are dealing in the
horizontal plane, which suppress impeller and die. Material placed on the areas where the two
halves of the die impact met. Deformation in the material to absorb energy. In this process the
material deforms the same on both sides; the contact time between the material and the die
shorter, less energy required compared with other forging processes and objects held
mechanically.
Once completed, all the average forging covered by crust must be cleaned. This can be
done by dipping it in acid, or tumbling bullet growth, depending on the size and composition of
objects during forging wrought If distortions occur, streamlining operations or put the size can
be made
Advantages of forging operation is smooth crystal structure of the metal, closed holes,
machining time that increasing physical properties. Carbon steel, alloy steel wrought iron,
aluminum and copper alloy magnesium alloy can be forged. The disadvantage is that the onset
of inclusion crust and expensive die so it is not economical to form the body in small amounts.
Penempan with closed die has several advantages compared with open die
forging with, among others, the use of more stringent, higher production capacity
and does not need any special skills.
Forging Press
In forging press, metal plastic deformation through suppression occurs very
slowly, which is different from the impact hammer that goes by fast. Vertical press
machine can be driven by mechanical or hydraulic. Pres somewhat faster
mechanics can produce between 4 and 90 MN (Mega Newton). Pressure required
TEKNIK MESIN FT UNY | TEMPA atau FORGING
to form the steel forging temperature varies between 20-190 MPa (Mega Pascal).
The pressure is calculated on the cross-section on the line dividing forging die.
In forging press in most of the energy can be absorbed by the workpiece
being in forging hammer part of the energy transmitted to the machine and
foundation. Reduction and the workpiece is much faster, therefore lower operating
costs. Many parts with irregular shapes and complicated can be forged more
economically with temap override process.
Upset forging
On average berpenampaan rod upset forging clamped in a heated die and the tip is
pressed so as to change the shape as shown in Figure 8. The length of the upset thing 2 or 3
times the diameter of the rod, if not the workpiece to be bent. Progressive perforation is often
done on the upset forging like to make artillery shell casing or cylinder radial engine.
Roll Forging
Short round rod diminished penempangannya or formed tapered with a roller machine.
Shape roller machine shown in Figure 10 where the roller is not completely round, but cut 25-75
% perforation to allow incoming material between rollers. Section groove in accordance with
the round given dihendakinya shape. When the rollers are in the open position, the operator put
the rods are heated in between the rollers. When the roller rotates, the rod is clamped by the
groove rollers and pushed toward the operator. When the roller is open, the rod is pushed back
and rolled again, or moved to the next exit to complete the formation of the next.
For mengerol wheels, tires and metals other similar objects required a slightly different
roller machine. In figure 11 looks process for mengerol wheel. When wheel spin diamer
gradually increases being increasingly thin plate and rim. Wheel rolled until it reaches a
diameter according to the size and then transferred to other pressing machine for the final
formation.
Forging an open mold is forging process that is conducted between two flat mold or
mold that looks very simple. Forging an open mold used in the initial formation of the
workpiece to forging a closed mold.
Open-die forgings; bendakerja pressed between two pieces of the mold (die) flat (almost flat) so
that the metal flow in the lateral direction without being hampered by the surface of the mold.
The forging operation known as upset forging of reducing high bendakerja and add to its
diameter.
Analysis of open-die forgings When the open-die forging is done under ideal conditions is no
friction between the surface bendakerja and mold, resulting in a homogeneous deformation, and
uniform metal radial flow, as shown in Figure 5:11.
Gambar 5.11 Deformasi homogen bendakerja silinder dalam operasi cetakan terbuka
In ideal conditions, the actual strain (true strain) can be determined by:
ln
in which:
h0
h
h0
h
F
A
Yf
= gaya, lb (N)
= luas penampang lintang, in 2 (mm2)
= tegangan alir, lb/in2 (MPa).
A cross-sectional area gradually increases during operation, and vice versa height h will be
reduced. Yf flow stress also increased as a result of hardening bendakerja, except the metal
perfectly plastic (eg in hot work). In these conditions, strain hardening exponent n = 0, and the
flow stress Yf = Y (yield strength of the metal). Force F will reach the maximum price at the end
of emphasis, namely when A and Yf has the highest price.
In the actual operation of the upset forging, deformation is not like in the picture 5:11, because
of the friction between bendakerja the mold surface, as shown in Figure 5:12.
Gambar 5.12 Deformasi sebenarnya bendakerja silinder dalam operasi cetakan terbuka
F Kf .Yf .A
This friction will increase if the work carried out in hot conditions and mold (die) remain in a
cold state. This can lead to:
(1) The increase in the coefficient of friction, and
(2) the transformation of heat from bendakerja to the surface / near surface of the mold, so that
the adjacent bendakerja more difficult to mold a deformable than the middle.
Both of these factors cause upset style that is actually larger than previously predicted. To
calculate the upset force approach can be used formula as follows:
dimana :
Kf
Kf 1
dimana :
D
h
0,4 D
h
= koefisien gesekan
= diameter benda kerja atau panjang bidang kontak dengan permukaan die,
in (mm)
= tinggi bendakerja, in (mm)
D2
22
3. .
V h .
9,426
4
4
in3
Kf 1
D2
22
.
3,142
4
4
in2
0,4 D
0,4 0,1 2
1
1,027
h
3,0
lb.
h0
3
ln
0,1823
h
2,5
lb/in2
h0 .A0 3 3,142
3,77
h
2,5
in2
A .
D2
4
Kf 1
4.A
4.3,77
2,19
in
0,4 D
0,4 0,1 2,19
1
1,035
h
2,5
lb.
The raw material of the workpiece in the cylindrical image similar to the different forms of work
in the open-die forging operations. At the time of the end position near the mold flash is formed
by the metal flow in the gap between cetakan.Walaupun flash should be cut at the end of the
operation, but in fact also beneficial to suppress the flow of metal to the gap between the mold,
so that the metal will fill the entire cavity of the mold. In hot forging, metal flow toward the gap
will be hampered because of the thin flash faster to cool down, the pressure on bendakerja will
grow and able to fill in all parts of the mold cavity, in order to obtain a better quality product.
The formula style used in the forging process is the same as that used in the formula style opendie forgings, but with a slightly different interpetasi:
F K f Yf A
dimana :
F
A
Yf
Kf
=
=
=
=
In hot forging price Yf = creep strength (yield) of metal at that temperature. Kf price increase
with increasing complexity of the shape / geometry of the product to be made. Price Kf for
various geometries of products can be seen in Table 5.1.
TEKNIK MESIN FT UNY | TEMPA atau FORGING
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Gambar 5.16 Aliran butir kristal (a) penempaan panas dengan penyelesaian akhir pemesinan,
(b) hasil pemesinan
A. KITCHEN WROUGHT
In carrying out the work of forging the necessary equipment and appliances,
such as kitchen forging, cutting tools, punching, stretcher tools, forming tools,
measuring tools, and other tools
B. FUNCTION KITCHEN WROUGHT
The main function of wrought kitchen is a place to burn the workpiece to be
formed. In addition to the work forming, forging may also be implemented in a
variety of jobs such as gilding, soften, connecting with car mats and other
wrought.
C. WROUGHT KITCHEN EQUIPMENT
Kitchen wrought remained generally used in workshops and permanently
placed on top of a foundation kuat.Suatu wrought kitchen requires air blower. Air
blower can be obtained through a variety of ways, either the traditional way, such
TEKNIK MESIN FT UNY | TEMPA atau FORGING
11
as kitchen forging press is still widely used in rural areas and the use of electric or
hand ventilator.
The main parts of the kitchen remains:
1. Chimney, function to draw the smoke and dust with natural pull system so
that air can be reduced population.
2. Fume hood, to direct the smoke into the chimney.
3. The furnace of fire, where install / burn the workpiece.
4. tubs, to cool the tool and the workpiece.
5. Valve regulator, to enter the intake air into the furnace.
6. The valve exhaust dust, to remove dust and slag residue burning slag.
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CLOSING
Conclusion
Forging metals are deformed due to the influence of traction, pressure and
bend that occurs in the heat and cold. Ideal forging process at a temperature of
800-1100 degrees Celsius and yellowish red. Steel should not be forged at
temperatures below 400 degrees Celsius as it would fragile blue brwarna. While
the steel is heated above 1200 degrees Celsius, the steel will be burnt and can not
be repaired anymore. Permanent control of the workpiece every minute until
melted lest workpiece. Each will do the job first forged check equipment available.
And use protective equipment when bekerja.Jagalah salvation yourself.
Suggestion
Not a lot of advice that I wrote but I just remind, among others:
1. When will undergo a job first check the existing fixtures.
2. Use the safety equipment provided.
TEKNIK MESIN FT UNY | TEMPA atau FORGING
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DAFTAR PUSTAKA
1. Wijaya, Novi. 2011. Laporan kerja tempa. http//:id.scribd.com/doc/54823293/Laporankerja-tempa. (diakses tgl 3Nov 2012 )
2. Murjito.2007. Laporan Penelitian berorientasi produk Jurusan Teknik Mesin Univ
Muhammadiyah Malang. http//:id.scribd.com/doc/110298475/Laporan-penelitian-PBP
(diakses tgl 3 Nov 2012 )
3. Annonim. 2011. Proses Penempaan http//:nd4s4ch.wordpress.com/2011/03/23/prosespenempaan-forging. (diakses tgl 3 Nov)
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