Forging Quiz

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CERAMIC AND CARBIDES DIE MATERIALS

CERAMIC AND CARBIDES DIE MATERIALS

Potential use of ceramics and carbides has been found be gaining interest for use in

warm and hot forging applications. Ceramic inserts and coatings are well established in

the machining industry for reducing tool wear and enhancing the tool per formance.

Some of the ceramic materials have marked improvements over the traditional hot work

die materials (Cr-Mo-W based steels) used in hot forging

 

 

 

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Forging defects

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.

A brief description of such defects and their remedial method is given below.

 Unfilled Section:

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.

Cold Shut:

This appears as a small cracks at the corners of the forging. This is caused manely by the improper design of die. Where in the corner and the fillet radie are small as a result of which metal does not flow properly into the corner and the ends up as a cold shut.

Scale Pits:

This is seen as irregular depurations 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 depurations on the forging surface.

Die Shift:

This is caused by the miss alignment of the die halve, making the two halve of the forging to be improper shape. 

 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.

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.

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Flashless (Enclosed Impression Die) Forging

Flashless Forging

Impression die forging is sometimes performed in totally enclosed impressions. The process is used to produce a near-net or net shape forging. The dies make no provision for flash because the process does not depend on the formation of flash to achieve complete filling. Actually, a thin fin or ring of flash may form in the clearance between the upper punch and die, but it is easily removed by blasting or tumbling operations, and does not require a trim die. The process is therefore called "flashless forging", and is sometimes called "enclosed die forging".

Enclosed dies are illustrated in Figure 5-14. In some cases the lower die may be split, allowing as-forged undercuts. Split die arrangements are illustrated in Figure 5-15.

The absence of flash is an obvious advantage for flashless forging over the conventional impression die process, but the process imposes additional requirements. For example, flashless forging is usually accomplished in one operation, and does not allow for progressive development of difficult-to-forge features through several stages of metal flow. In addition, the volume of metal in the workpiece must be controlled within very narrow limits to achieve complete filling of the cavity without developing extreme pressures. It takes some very well controlled preforming steps to accomplish this precise weight control in the final die.

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Precision Forging

Precision Forging

Modern technological advances in the metal forging process and in the design of die, have allowed for the development of precision forging. Precision forging may produce some or no flash and the forged metal part will be at or near its final dimensions, requiring little or no finishing. The number of manufacturing operations is reduced as well as the material wasted. In addition, precision forging can manufacture more complex parts with thinner sections, reduced draft angles, and closer tolerances. The disadvantages of these advanced forging methods are that special machinery and die are needed, also more careful control of the manufacturing process is required. In precision forging, the amount of material in the work, as well as the flow of that material through the mold must be accurately determined. Other factors in the process such as the positioning of the work piece in the cavity must also be performed precisely.

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Impression Die Forging

Compression of workpart by dies with inverse of desired part shape
Flash is formed by metal that flows beyond die cavity into small gap between die plates
Flash must be later trimmed, but it serves an important function during compression:
–
As flash forms, friction resists continued metal flow into gap,constraining metal to fill die cavity

Impression‑Die Forging Practice

•Several forming steps are often required
-With separate die cavities for each step
•Beginning steps redistribute metal for more uniform deformation and desired metallurgical structure in subsequent steps
•Final steps bring the part to final geometry

Cogging

Successively reducing the thickness of a bar with open die forging
•Also called drawing out
•Reducing the thickness of a long section of a bar without
excessive forces or machining

a cogging operation on a rectangular bar. Blacksmiths use this process to reduce the thickness of bars by hammering the part on an anvil. Note the barreling of the workpiece.

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Forging

Forging is the process by which metal is heated and is shaped by plastic deformation by suitably applying compressive force. Usually the compressive force is in the form of hammer blows using a power hammer or a press.
Forging refines the grain structure and improves physical properties of the metal. With proper design, the grain flow can be oriented in the direction of principal stresses encountered in actual use. Grain flow is the direction of the pattern that the crystals take during plastic deformation. Physical properties (such as strength, ductility and toughness) are much better in a forging than in the base metal, which has, crystals randomly oriented.

Forgings are consistent from piece to piece, without any of the porosity, voids, inclusions and other defects. Thus, finishing operations such as machining do not expose voids, because there aren't any. Also coating operations such as plating or painting are straightforward due to a good surface, which needs very little preparation.
Forgings yield parts that have high strength to weight ratio-thus are often used in the design of aircraft frame members.
A Forged metal can result in the following

•	Increase length, decrease cross-section, called drawing out the metal.
•	Decrease length, increase cross-section, called upsetting the metal.
•	Change length, change cross-section, by squeezing in closed impression dies. This results in favorable grain flow for strong parts

 

 

 

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Open Die Forging

Open die forging involves the shaping of heated metal parts between a top die attached to a ram and a bottom die attached to a hammer anvil or press bed. Metal parts are worked above their recrystallization temperatures-ranging from 1900°F to 2400°F for steel-and gradually shaped into the desired configuration through the skillful hammering or pressing of the work piece.

While impression or closed die forging confines the metal in dies, open die forging is distinguished by the fact that the metal is never completely confined or restrained in the dies. Most open die forgings are produced on flat dies. However, round swaging dies, V-dies, mandrels, pins and loose tools are also used depending on the desired part configuration and its size.

Although the open die forging process is often associated with larger, simpler-shaped parts such as bars, blanks, rings, hollows or spindles, in fact it can be considered the ultimate option in "custom-designed" metal components. High-strength, long-life parts optimized in terms of both mechanical properties and structural integrity are today produced in sizes that range from a few pounds to hundreds of tons in weight. In addition, advanced forge shops now offer shapes that were never before thought capable of being produced by the open die forging process.

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