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(MF F313)
BITS Pilani
Pilani Campus
K S SANGWAN|L5|August 20
Outline
Forging analysis
Types of forgings
Strip Forging
Assumption
forging forcef attains its maximum value at the end of the
operation
is constant
variation of stress field along y-axis is negligible
plane strain case
entire w/p is plastic in state during the process
h d x 2 dx 0..........
......(1)
[ now letx and p are principal stresses
it being a case of plane area
2 ( 1 p ) / 2
applyVON MISES criteria,
p x 2k ]
dp d x ..........
....(2)
puting in (1)
h dp 2 dr 0
dp ( 2 / h ) dx..........
........(3)
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equ(3)becomes
dp (2 p / h )dx
dp / p 2 x / h c1
to find c1
p ps
p s ( 2k / h) x s c 2
c 2 p s ( 2k / h) x s
ln( p / 2k ) 2 x / h
or p / 2k e 2 x / h
p1 2ke 2 x / h ..........(4)
x xs ,
0 xl
c2 2k[e 2 xs / h x s / h]
p 2k[e 2 xs / h ( x xs ) / h].........(6)
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TO FIND
dx xs ,
ps k ps k /
puting this in equ(4), weget
ps k / 2ke[ 2 xs / h ]
1 / 2 e 2 xs / h
or 2 xs / h ln(1 / 2 )
xs h / 2 ln(1 / 2 )
puting xs in equ(6), we get
p 2k[e ( 2 / h )(h / 2 ) ln(1/ 2 ) 1 / h{x h / 2 ln(1 / 2 )}]
2k[1 / 2 1 / h{x h / 2 ln(1 / 2 )}]
p2 2k[1 / 2 {1 ln(1 / 2 ) x / h}]............(7)
xs x l
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xs
DISC FORGING
r rd .h d r rd .h r rd .h 2rddr 0
d r .h 2dr 0 ______________________________________(1)
Let , r , and p are Pr incipal Stresses
Therefore , Putting these values in eq n
( 1 2 ) 2 ( 2 3 ) 2 ( 3 1 ) 2 6k 2
We get
r p 3k ________________________________________(2)
or
d r dp
Put in eq n (1)
hdp 2dr 0 ________________________________________(3)
p
n
Put in eq (3)
hdp 2pdr 0
dp / p (2 / h)dr
Integrating ,
ln p (2 / h)r C1
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To f ind C1
r R, r 0,
Theref ore f rom eq n ( 2)
p
3k
ln( 3k ) ( 2 / h) R C1
or C1 /( 3k ) e ( 2 / h ) R
or C1
3k e ( 2 / h ) R
Hence, ln p ( 2 / h) r ln
or
p sl
3k e ( 2 / h ) R
3k e ( 2 / h ) R . e ( 2 / h ) r
rs r R
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also p s
Putting, k in eq n (3)
hdp 2kdr 0
or dp (2k / h)dr
Integrating ,
To Find C2 :
At r rs ,
p ps
Putting in eq n (5),
p s (2k / h)rs C2
or C2 p s (2k / h)rs
From eq n (4), by putting r rs and put the value in aboveeq n
C 2 3k e ( 2 / h )(R rs ) (2k / h)rs
Putting C 2 in eq n (5), we get
p (2k / h)r (2k / h)rs 3k e ( 2 / h )(R rs )
p (2k / h)(rs r ) 3k e ( 2 / h )(R rs ) _______________________(6)
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To Find rs :
At r rs , k p s
or
ps k /
3k e ( 2 / h )(R rs )
e ( 2 / h )(R rs ) 1 / 3
(2 / h)( R rs ) ln(1 / 3 )
R rs ( h / 2 ) ln(1 / 3 )
rs R (h / 2 ) ln(1 / 3 )
Putting , rs value in eq n (6)
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(2k / h)R (h / 2 ) ln(1 /
3 ) r
3 )
3 )
p2
3 ) ______________(7) , (0 r rs )
rs
F p 2 .2r.dr p1 .2r.dr
R
rs
2 p 2 .r.dr p1 .r.dr
0
rs
rs
rs
( 2 / h )( R r )
2 (2k / h)( R r )r.dr 2 (k / ) 1 ln( 3 ) r.dr 2 3ke
.r.dr
rs
2 (2k / h) ( Rr 2 / 2) (r 3 / 3)
rs
0
rs
0
R
rs
Types of Forging
Smith forging
Drop forging
Press forging
Upset forging
Swaging
Roll forging
Roll Forging
Die Features
Fillet radius
Draft
Flash gutter
Shrinkage allowance (hot forging)
Forging Defects
Unfilled sections less metal, improper heating,
misplacement of metal
Scale pits scale in die
Mismatched forging misalignment of two halves of die
Barreling low lubrication
Laps thin web
Internal cracks thick web
Forging Defects
(a) Laps formed by web buckling during forging; web thickness should be increased
to avoid this problem.
(b) (b) Internal defects caused by oversized billet; die cavities are filled prematurely,
and the material at the center flows past the filled regions as the dies close.
BITS Pilani, Pilani Campus
Thanks