AUTOMOBILE MANUFACTURING PROCESSES 2010

1.7 Advantages of forging

Strength:
Forging reduces the failures. In this process work-
piece yields with high strength to weight ratio.
Due to this, it can be able to withstand
fluctuating stress caused by sudden shock
loading.

I. Metal conservation:

Practically there is no waste of metals.

II. Weight saving:

Strong thin-walled parts may be produced without damaging

important physical requirements.

III. Machining time:

Forging can be made to close tolerances, which reduces

machining time for finishing operations of the products.

Speed of production:
High rate of production is possible.

IV. Incorporation in welded structures:

4
Dhaigude.P.B.
AUTOMOBILE MANUFACTURING PROCESSES 2010

Parts can be welded easily due to fibrous structure.

V. It maintains uniform and same quality all over parts.

VI. Close tolerances.

VII. Smooth surface finish.

1.8 Disadvantages of forging parts

I. High tool cost.

II. High tool maintenance.

III. No cord holes.

IV. Limitation in size and shape.

V. Heat treatment process increases cost of the product.

VI. Brittle materials like cast iron can not be forged.

VII. Complex shape can not be produced by forging.

1.9 Classification of forging process:

Mainly forging process classified into two parts.

I. Open die forging:

a) Hand forging

b) Power forging:

i. Hammer forging

4
Dhaigude.P.B.
AUTOMOBILE MANUFACTURING PROCESSES 2010

ii. Press forging

II. Close die forging:

a) Drop forging

b) Press forging

c) Machine forging

I. Open die forging:

It is the simplest forging process. This process also known as

smith die forging or flat die forging. A solid workpiece placed between
two flat face dies as shown in fig.1.1 (a) and reduces their height by
compressing it.

Fig. 1.1 Open Die Forging Processes

The die surfaces have some cavity to produce relatively

simple forging. Deformation of workpiece takes place in ideal condition
as shown in fig.1.1 (b). Due to constant volume, reduction in height
increases the diameter of forged part. But in actual working conditions

4
Dhaigude.P.B.
AUTOMOBILE MANUFACTURING PROCESSES 2010

part gets developed in barrel shape as shown in fig.1.1 (c). This

barreling is caused due to friction force between workpiece and die
surfaces. Barreling can be reduced easily with help of lubricant.

Smith die forging process sub-divided into two parts

a) Hand process:

According to the name this process purely done by hand. The

forging is done on a anvil by hammering the workpiece at suitable
temperature. This temperature attained by heating the workpiece with
tongs.

Hand forging consist of two formers as shown in fig.1.2.

These formers are made of high carbon steel in different size to suit
various types of workpiece. It has two formers top and bottom
formers. Bottom formers also known as fuller. Working edges of the
fullers and formers are normally rounded. These are used for making
necks by reducing cross-section of a workpiece.

Generally are used in maintenance shops as well as rework

area. But now a days, a new forging process is developed known as
power forging.

b) Power forging:

Heavy machine parts can not be forged by hand. Low blow of

a hand or hammer is not able to produce a great degree of
deformation in a workpiece.

The machine or equipments driven by external source having

high power are used in power forging.

4
Dhaigude.P.B.
AUTOMOBILE MANUFACTURING PROCESSES 2010

Power forging also sub-divided into two parts

i. Hammer forging:

Machine which is work by blow or impact to perform forging

process is known as hammer forging

ii. Press forging:

Machine which is work on pressure to perform forging process

is known as press forging.

II. Close die forging:

In open die forging Complex shape with great accuracy is

very difficult to forged. Close die forging process consist of specially
prepared dies to manufacturing forged parts in large quantities. It is
also known as impression die forging.

Fig. 1.3 Close Die Forging

4
Dhaigude.P.B.
AUTOMOBILE MANUFACTURING PROCESSES 2010

It consist of two dies as shown in fig.1.3. the workpiece takes

the shape of the die cavities ( impression ) during forging process.
Some materials comes outwards and forms a flash. The flash has a
very important role in the grain flow of material in close die forging.
Thin flash cools very easily. Flash have frictional resistance gives high
pressure to the material in die cavity. So it helps to filling of die cavity.

Generally this process is used for mass production with high

degree of accuracy.

This process sub-divided into two parts

a) Drop forging:

Drop forging is used when mass production of identical parts is

required. It is also called as stamping. It consist of special type of
hammer known as drop hammer or drop stamp.

Perfectly made steel dies are used for forging. these dies are
made into two parts as shown in fig.1.4. One part is connected to the
top side and other part is fastened to the anvil block at the bottom
side. The top part of the die is raised by mechanical links to a certain
height. The heated metal placed accurately in the bottom part of the
die. The top part of the die is then allowed to fall suddenly. This gives
a high blow and completes the workpiece in a single operation. This
process done due to squeezing of the metal into the die cavities.

The devices are used for raising the top part of the die is given
below

i. Belt

ii. Rope

iii. Friction rolls and board.

4
Dhaigude.P.B.
AUTOMOBILE MANUFACTURING PROCESSES 2010

Working process:

At

b) Press forging:

The machine which is work on pressure to perform forging

process is known as press forging. This process consist of slow
squeezing of metal in closed impression dies, instead of Appling
repeated blow by hammers.

Generally two types of presses are used

i. Hydraulic presses:

These presses are used for heavy work. Hydraulic presses are
less faster than mechanical presses. But hydraulic presses produce
greater squeezing force than mechanical presses.

ii. mechanical presses:

These presses are used for light work. Mechanical presses are
faster than hydraulic presses. But mechanical presses not able to
produce greater squeezing force than hydraulic presses.

In this presses more complicated shapes and better

dimensional accuracy can be easily achieved. The alignment of the die
is very easy as compared to drop hammer forging. These presses and
dies have longer life than hammer forging. Press forging requires less
skill operators. These presses produce less noise and vibration.

4
Dhaigude.P.B.
AUTOMOBILE MANUFACTURING PROCESSES 2010

c) Machine forging:

This process also known as hot heading or up-setting.

This process consist of applying pressure longitudinally on a hot bar
clamped or gripped between grooved dies. Forging is done on the
end of the bar. Forging is done on various shapes of metals. But
most commonly used shape is round shape metals. The equipments
used for forging is forging machine or up-setter. Generally it gives
forging pressure in a horizontal directions.

Fig. 1.5 Machine Forging

These dies are so designed such that complete operation is

performed in several stages and gradually final shape is obtained.
Operation performed with a die and punch called heading tool. Fig.
1.5 shows step by step operation done on the round bar. Die is either
made hallow to receive the round bar through it or in two parts to
open out and receive the bar. Heading tool is advanced in to die.
4
Dhaigude.P.B.
AUTOMOBILE MANUFACTURING PROCESSES 2010

Many strokes of the heading tool may be needed to complete the

forging. In this process dies does not have draft as well as flash, so it
gives better dimensional accuracy.

1.10 Difference between drop forging and press forging:

Sr.
Drop forging Press forging
No.
1) This process involves fast This process involves slow
squeezing of metal in dies by squeezing of metal in dies by
applying repeated blows by applying pressure force.
hammers.
2) The dies used relatively more The dies used relatively less
draft and therefore more draft and therefore more
complicated shape can not be complicated shape can be
forged. forged.
3) Alignment of two dies halves is Alignment of two dies halves is
difficult. easy.
4) The life of machines and dies The life of presses and dies are
are shorter. longer.
5) This process requires highly This process does not requires
skilled operator. highly skilled operator.
6) This process have more noise This process have less noise
and vibrations. and vibrations.
7) Production rate is slower. Production rate is faster.
8) Less dimensional accuracy. Better dimensional accuracy.

4
Dhaigude.P.B.
AUTOMOBILE MANUFACTURING PROCESSES 2010

1.11 Difference between open die forging and close die

forging:
Sr.
Open die forging Close die forging
No.
1) It is the simplest forging It is the complex forging
process. process.
2) This process requires simple This process requires complex
and inexpensive dies. and expensive dies.
3) It is useful only for small scale It is useful for small scale as
production. well as large scale production.
4) It is very difficult to hold close It is very easy to maintain close
tolerances. tolerances.
5) Relatively poor utilization of Relatively good utilization of
materials. materials.
6) This process requires highly This process does not requires
skilled operator. highly skilled operator.
7) This forging process have less This forging process have better
dimensional accuracy. dimensional accuracy.
8) This forging process have less This forging process have better
reproducibility. reproducibility.
9) This forging process have less This forging process have high
die cost. die cost.
10) In this process machining is In this process machining is not
necessary to obtain final shape. necessary to obtain final shape.

1.12 Forging die design:

4
Dhaigude.P.B.
AUTOMOBILE MANUFACTURING PROCESSES 2010

The design of forging dies requires a knowledge of

strength, ductility, sensitivity to deformation rate and melting point
of the workpiece material.

Fig. 1.6 Standard Terminology of Forging Die

The terminology for forging die is as shown in fig. 1.6.

Some of these consideration are similar to those for casting. For
most of the forging, the parting line is usually at the largest cross-
section of the part for symmetrical parts, the parting line at the
center of the forging. But for more complex shapes the parting line
may not be lie in the center of the forging.
The flash materials allowed to flow into a gutter, so
that extra flash does not increase the forging load unnecessarily. The
length of the land is usually 2 to 5 times the flash thickness. Number
of gutter design have been developed throughout the years.
To removal of the workpiece from the dies in almost
all forging process draft angles are necessary. At the time of cooling,
4
Dhaigude.P.B.
AUTOMOBILE MANUFACTURING PROCESSES 2010

forging shrinks both radialy and longitudinally. To overcome this

cause, internal draft angles are made larger than external draft
angles. Internal draft angles are about 7° to 10°, and external draft
angles are about 3° to 5°.
Selection of proper radii for corners and fillets is
important to give smooth flow of metal in a die cavity as well as to
improve die life. Small radii and fillets are not allowed due to stress
concentration and fatigue cracking of the dies.
Allowances are provided in forging die design because
machining of forging of forging may be necessary to obtain final
desired dimensional as well as surface finish. To produce a smooth
and accurate cavity with parting plane more care is required.
In a die, better and economical results are will be
obtained if the following points are considered:
I. The die should part along a single flat plane, if at all possible. If
not then parting plane should follow counter of the workpiece.
II. The parting line should be lies in one plane and not close to the
upper or lower edge.
III. Proper draft angles should be provided – at least 3° for
aluminum and 5° to 7° for steel. Also 1° to 5° draft is provided in
press forging and 3° to 10° in drop forging.
IV. Filets radii should be provided.
V. Ribs should be low and wide.
VI. The various sections should be balanced to avoid extreme
differences in metal flow.
VII. Full advantage should be taken of fiber flow lines.
VIII. Dimensional tolerances should not be closer than necessary.
IX. Forged component should be easily able to achive a radial flow
grains or fibers.

4
Dhaigude.P.B.
AUTOMOBILE MANUFACTURING PROCESSES 2010

X. Too thin section should be avoided for easy flow of metal.

1.13 Die materials and lubricants:

The die material and lubrication is the important
aspects of forging.

I. Die materials:
In most of the forging operation large parts are forged
at elevated temperature. Therefore the general requirements for die
materials are:
a) Good strength and toughness at elevated temperatures.
b) Good harden ability and ability to harden uniformaly.
c) Resistance to mechanical and thermal shocks.
d) It should have high wear resistance.

Selection of proper die material depends on following

factors:
i. Size of the die components.
ii. The properties and composition of the workpiece.
iii. Complexity of shape.
iv. Forging temperature.
v. Cost of the die material.
vi. Number of forging is required.
vii. Heat transfer from hot workpiece to die.
Common die materials are tool and die steel
containing chromium, nickel, molybdenum, and vanadium.
Dies are made from die block , which are forged from
casting. These dies are machined and finished to the desired
shape and surface finish.

4
Dhaigude.P.B.
AUTOMOBILE MANUFACTURING PROCESSES 2010

II. Lubrication:
Lubricants generally reduces friction and wear. They
also act as thermal conductor between hot workpiece and cool dies.
It can slows the cooling rate of workpiece and improving metal flow
or grain flow. It also act as a parting agent.
Wide variety of lubricants can be used in forging:

a) For hot forging:

i. Graphite.
ii. Glass.
iii. Molybdenum disulfide.
In hot forging lubricants are usually applied
directly in to the dies.

b) For cold forging:

i. Mineral oils.
ii. Soaps.
In cold forging, Lubricants are generally
applied on the workpiece.

1.14 Defects in forging:

All defects in forging are given below with the
reasons:

a) Defective structure of metal; Reason – defective original metal.

4
Dhaigude.P.B.
AUTOMOBILE MANUFACTURING PROCESSES 2010

b) Presence of cold shuts or cracks at corners; Reason – improper

forging and faulty die design.
c) Incomplete component; Reason – less metal used, faulty die
design and inadequate metal flow.
d) Mismatched forging; Reason – die halves not properly aligned.
e) Burnt and overheated metal; Reason – improper heating.
f) Fiber flow lines or grain flow lines disconnected; Reason – very
rapid plastic flow of metal.
g) Scale pits; Reason – formed by squeezing of scale into metal
during forging.
h) Oversize components; Reason – worn out dies, incorrect dies.

Also fig. 1.7 shows common examples of defects in forged parts

4
Dhaigude.P.B.
AUTOMOBILE MANUFACTURING PROCESSES 2010

Fig. 1.7 Examples Of Defects In Forged Parts

1.15 Forged parts:

I. Gear blank:

It can be made by upsetting the bar stock. The pattern of the grain flow
lines in the bar stock is as shown in fig. 1.8 (a). When bar stock is
placed in dies such that the flow lines are vertical. The grain pattern
produced will be radial and gear blank will give greatest strength to the

4
Dhaigude.P.B.
AUTOMOBILE MANUFACTURING PROCESSES 2010

teeth as shown in fig. 1.8 (b).

Fig 1.8 Forging Sequence For Gear Blank

All teeth will be equally strong. This is desired because each

tooth considered as a cantilever beam and grain flow lines will be
parallel with expected tensile and compressive stress along the face of
the gear teeth. If the bar stock is placed in the die in such a manner
that its flow lines are horizontal, then the grain pattern produced will be
shown in fig. 1.8 (c). the teeth cut on such blank will not be of the same

4
Dhaigude.P.B.
AUTOMOBILE MANUFACTURING PROCESSES 2010

strength . because gear blank have expected stresses are perpendicular

to the flow lines of bar stock.

II. Connecting rod:

It can be made by forging the bar stock. The blank shape gradually
changes, as shown in fig. 1.9 (a) of connecting rod.

Fig. 1.9 Forging Sequence For Connecting Rod

4
Dhaigude.P.B.
AUTOMOBILE MANUFACTURING PROCESSES 2010

Performing processes, such as fullering and edging [fig. 1.9(b) and fig.
1.9(c)] are used to distribute the material into various regions of the
blank. In fullering, material is distributed away from an area. In
edging, it is gathered into a localized area. The part is then formed into
the rough shape of a connecting rod by a process called blocking using
blocker dies. The final operation is the finishing of the forging in close
die forging that give the forging its final shape. The flash is removed

4
Dhaigude.P.B.
AUTOMOBILE MANUFACTURING PROCESSES 2010

usually by a trimming operation (fig. 1.9)

Fig 1.10 Practical Forging Process For Connecting Rod

4
Dhaigude.P.B.