Forging

Dr. Ibraheem Sabry

 Definition of Forging

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Forging is a compressive
metal forming process,

Modern Academy Chapter 6 Forging

involving shaping a metal
piece by hammer or press.
Processes that induce plastic
deformation through localized
compressive forces applied through
dies

The figure shows an opendie forging

process. Note
the red hot bar stock in
place.
 Definition of Forging

Modern Academy Chapter 6 Forging

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 Connecting rods

Engine crankshafts
Products of forging

Aircraft structural components

Modern Academy Chapter 6 Forging

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 Jet engine turbine parts

Basic shape of small parts

Products of forging

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 Press tool
dies

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 press Forging

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 Apply gradual pressure to accomplish compression
operation

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􀂃 Types:
1. Mechanical press [equipment inverts rotation of
drive motor into linear motion of ram]
 These presses are stroke limited, with speeds
varying from a maximum at the center of the stroke to
zero at the bottom.
 The force available depends on the stroke position
and becomes extremely large at the bottom-dead
center position; thus proper setup is essential to avoid
breaking the dies or other
 press Forging

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Modern Academy Chapter 6 Forging
 Apply gradual pressure to accomplish
compression operation
􀂃 Types:
2. Hydraulic press - hydraulic piston
actuates ram: these presses have a
constant low speed and are load
limited.
 Large amounts of energy can be
transmitted to the workpiece by a
constant load that is available
throughout the stroke.
 press Forging

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• Apply gradual pressure to accomplish compression
operation

Modern Academy Chapter 6 Forging

􀂃 Types:
3. Screw press - screw mechanism drives ram :
these presses deriving their energy from a flywheel
 Screw presses transmits the forging load through a
vertical screw.
 These presses are energy limited and can be used
for a variety of forging operations.
 The presses are particularly suitable for producing
small quantities, producing parts requiring precision
( such as turbine blades), and for controlling the
ram speed.
 Hydraulic Press

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 Mechanical Press

Modern Academy Chapter 6 Forging

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 Advantages of Forging Processes

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• Hardness and Ductility

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• Grain Flow

• Tougher Metal

• Intricate Shapes

• Impurity Uniformity
 • Cost

• Tolerances

• Maintenance
• High Temperature
Disadvantages of Forging Processes

Modern Academy Chapter 6 Forging

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 Open-die Hammer Forging

Modern Academy Chapter 6 Forging

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 Types of Forging Operations

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1. Open-die forging – work part is compressed
between two flat dies, allowing metal to flow

Modern Academy Chapter 6 Forging

laterally with minimum constraint

2. Impression-die forging - die contains cavity or

impression that is imparted to work part
• Metal flow is constrained so that flash is created

3. Flashless forging (closed die forging) - work

part is completely constrained in die
• No excess flash is created
 Types of Forging Dies

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Open-die forging - work is compressed between two flat dies, allowing
metal to flow laterally with minimum constraint

Modern Academy Chapter 6 Forging

Open-Die Forging
•(a) Ideal deformation of a solid • (b) Deformation in upsetting
cylindrical specimen compressed with friction at the die-workpiece
between flat frictionless dies. interfaces.
Forging(FULLERING,FLATTENING,SWAGING)

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Load-Stroke Curve in Closed-Die Forging

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• Typical load-stroke
curve for closed-die
forging. Note the
sharp increase in load
after the flash begins
to form. In hot-forging
operations, the flash
requires high levels of
stress, because it is
thin-that is, it has a
small h-and cooler
than the bulk of the
forging.
 Open-die forging

Modern Academy Chapter 6 Forging

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 Open-die forging

Modern Academy Chapter 6 Forging

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 Open-die forging

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Modern Academy Chapter 6 Forging
The reduction in height is defined as :
ℎ𝑜 −ℎ1
* 100%
ℎ𝑜

And the engineering strain is

ℎ𝑜 −ℎ1
e1 =
ℎ𝑜
 Open-die forging with No Friction

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• If no friction occurs between work and die
surfaces, then homogeneous deformation

Modern Academy Chapter 6 Forging

occurs, so that radial flow is uniform
throughout workpart height and true strain is
given by:
ho
  ln
h
• where ho= starting height; and h = height at
some point during compression
• At h = final value hf, true strain reaches
maximum value
 Open-die forging

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1. • Fullering

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2. • Edging
3. Cogging

• These operations are used to

perform the workpiece for closed die
forging
 Open-die forging

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• Fullering

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• Reducing work piece cross section to prepare
for subsequent shaping action. Dies with
convex surface cavity are used.
 • Edging

concave surface cavity.

Open-die forging

• Similar to Fullering, but the dies have

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 Open-die forging

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• Cogging

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• Open dies with flat or slightly contoured
surfaces to reduce cross-section and to
increase length.
 Open-die forging with friction

Modern Academy Chapter 6 Forging

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 Types of Forging Dies

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Closed -die forging - die contains cavity or impression that is imparted
to workpart. Metal flow is constrained so that ‫ة‬flash is

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created
 Types of Forging Dies(Closed -die forging )

Modern Academy Chapter 6 Forging

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 Types of Forging Dies(Closed -die forging )

Modern Academy Chapter 6 Forging

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 Types of Forging Dies

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Flashless

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Flashless forging – work part is completely
constrained in die. No excess flash is created
 Roll Forging

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In roll forging, the cross-sectional area of a bar is
reduced and altered in shape by passing it through a

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pair or sets of grooved rolls of various shape.

• Fast
• Widely Used
• Long, Tapered or
Symmetrical Sections
 Roll Forging

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 Upset forging

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• Upsetting

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– To decrease part length and increase its cross
section
• Heading
– Heads of tool machine
 Upset Forging

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(a) Heading operation, to form heads on fasteners such as nails and
rivets. (b) Sequence of operations to produce a bolt head by
heading.
 Upset Forging Heading

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Modern Academy Chapter 6 Forging
Examples of heading (upset forging) 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 .
 Hill friction

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Original part

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With friction
Without friction With friction

Without lubricant and

With lubricant Without lubricant High Pressure in center
Pressure constant Increase Pressure Overcoming friction force
with force
 Hill friction

low friction

high friction

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 Grin size

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 Grain Flow Comparison

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Each process has its own advantages and limitations
regarding external and internal characteristics, material
properties, dimensional accuracy, surface finish and the
economics of production
 Grain Flow Comparison

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The formation of a grain structure in forged parts is

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elongated
in the direction of the deformation.
• The metal flow during forging provides fibrous
microstructure
(revealed by etching). This structure gives better mechanical
properties in the plane of maximum strain but (perhaps)
lower across the thickness.
• The workpiece often undergo recrystallisation, therefore,
provide finer grains compared to the cast dendritic structure
resulting in improved mechanical prop
 Orientation of Grains

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Castings Forgings

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Cast structure
Fibre structure in forged steels

Mainly epitaxial, dendritic Redistribution of grains in the

or equiaxed grains
working directions
Orientation of Grains

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Parting-line

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location and its
influence on
grain-flow
patterns in a
channel section
forging
a. Parting lines resulting
in metal flow patterns
that cause defects
b. Parting lines resulting
in smooth flow lines at
stressed sections
 Example

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 Upsetting ratio

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 Upsetting ratio

Modern Academy Chapter 6 Forging

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 Upsetting force

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 Upsetting

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 Upsetting

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 Example

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Using open-die forging operation, a solid cylindrical piece of 304 stainless
steel having 100 mm dia x 72 mm height is reduced in the height to 60 mm
at room temperature. Assuming the coefficient of friction as 0.22 and the

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flow stress for this material at the required true strain as 1000 MPa,
calculate the forging force at the end of stroke.

Solution . Initial diameter = 100 mm

Initial height = 72 mm

Final height = 60 mm

If final diameter is d, (100)2 x 72 = d2 x 60

i.e. d =110 mm
 Example

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 Ex.

Modern Academy Chapter 6 Forging

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 Ex.

Modern Academy Chapter 6 Forging

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 Ex.

Modern Academy Chapter 6 Forging

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 Example

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The aim is to produce spheres 30 mm in diameter out of 42
CrMo 4. The initial diameter is to be set in such a way that the

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upsetting ratio is s = 2.6.