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residual stresses in
forging
Metal
forging
Forging
defects
Geometrical
defect
NonGeometric
al defects
The
residual
stresses
Metal forging
Metal forging is a metal
forming process that
involves applying
compressive forces to a work
piece to deformed it, and
create a desired geometric
change to the material. The
forging process in very
important in industrial metal
manufacture, particularly in
the extensive iron and steel
manufacturing industry.
Forging defects
Though forging process give generally prior quality
product compared other manufacturing processes.
There are some defects that are lightly to come a
proper care is not taken in forging process design.
Forging defect can be categorized into two broad
categories:
Geometrical defect
Non geometrical defect
Geometrical defect
The main types of geometrical defect are:
Laps and fold
Underfills
Overfills
Piping
Forging shape does not match design
Die deflection, yielding or wear
Eccentricity or bucking
Cold Shut
This appears as a small cracks at the corners of the forging. This is caused mainly by
the improper design of die. Where in the corner and the fillet radii are small as a result
of which metal does not flow properly into the corner and the ends up as a cold shut.
A cold shut is a discontinuity produced when two surfaces of metal fold against each
other without welding completely. A cold shut can occur when a flash or fin produced
by one forging operation is pressed into the metal surface during a subsequent
operation.
Underfills
Underfills are another geometrical defect commonly caused by
inadequate press force, energy and/or power. In this some
section of the die cavity are not completely filled by the flowing
metal. The causes of this defects are improper design of the
forging die or using forging techniques.
Underfills
Buckling
Shearing
Flakes
These are basically internal ruptures caused by the improper
cooling of the large forging. Rapid cooling causes the exterior
to cool quickly causing internal fractures. This can be
remedied by following proper cooling practices.
Cracking
Cracking at the flash of
closed-die forgings is another
surface defect, since the
crack generally penetrates
into the body of the forging
when the flash is trimmed of
his type of cracking is more
prevalent the thinner the
flash in relation to the
original thickness of the
metal. Flash cracking can be
avoided by increasing the
flash thickness or by
relocating the flash to a less
Scale Pits
This is seen as irregular deputations on the surface of the
forging. This is primarily caused because of improper
cleaning of the stock used for forging. The oxide and scale
gets embedded into the finish forging surface. When the
forging is cleaned by pickling, these are seen as
deputations on the forging surface.
Die Shift:
This is caused by the miss alignment of the die halve, making
the two halves of the forging to be improper shape.
Improper Grain Flow:
This is caused by the improper design of the die, which makes
the flow of the metal not flowing the final interred direction.
REFERENCES:
Abbaschian, Reed-Hill. Physical
Metallurgy Principles. 4th edition. 2009
Beer & Johnston (2006). Mechanics of
Materials (5th edition). McGraw Hill.
Robert S Williams Metallurgy and
metallurgical engineering series.
McGraw-Hill Book Co; 5th edition (1948).