Download - Types of Forging Processes _ Forging Industry Association

8/1/2015 TypesofForgingProcesses|ForgingIndustryAssociation

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Therearebasicallythreemethods(orprocesses)tomakeaforgedpart.

1. ImpressionDieForging

2. ColdForging

3. OpenDieForging

4. SeamlessRolledRingForging

ImpressionDieForgingImpressiondieforgingpoundsorpressesmetalbetweentwodies(calledtooling)thatcontainaprecutprofileofthedesiredpart.Partsfromafewouncesto60,000lbs.canbemadeusingthisprocess.Someofthesmallerpartsareactuallyforgedcold.

PROCESSOPERATIONSGraphicaldepictionofprocesssteps.

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ProcessCapabilities

Commonlyreferredtoascloseddieforging,impressiondieforgingofsteel,aluminum,titaniumandotheralloyscanproduceanalmostlimitlessvarietyof3Dshapesthatrangeinweightfrommereouncesuptomorethan25tons.Impressiondieforgingsareroutinelyproducedonhydraulicpresses,mechanicalpressesandhammers,withcapacitiesupto50,000tons,20,000tonsand50,000lbs.respectively.

Asthenameimplies,twoormorediescontainingimpressionsofthepartshapearebroughttogetherasforgingstockundergoesplasticdeformation.Becausemetalflowisrestrictedbythediecontours,thisprocesscanyieldmorecomplexshapesandclosertolerancesthanopendieforgingprocesses.Additionalflexibilityinformingbothsymmetricalandnonsymmetricalshapescomesfromvariouspreformingoperations(sometimesbending)priortoforginginfinisherdies.

Partgeometry'srangefromsomeoftheeasiesttoforgesimplesphericalshapes,blocklikerectangularsolids,anddisclikeconfigurationstothemostintricatecomponentswiththinandlongsectionsthatincorporatethinwebsandrelativelyhighverticalprojectionslikeribsandbosses.Althoughmanypartsaregenerallysymmetrical,othersincorporateallsortsofdesignelements(flanges,protrusions,holes,cavities,pockets,etc.)thatcombinetomaketheforgingverynonsymmetrical.Inaddition,partscanbebentorcurvedinoneorseveralplanes,whethertheyarebasicallylongitudinal,equidimensionalorflat.

Mostengineeringmetalsandalloyscanbeforgedviaconventionalimpressiondieprocesses,amongthem:carbonandalloysteels,toolsteels,andstainless,aluminumandcopperalloys,andcertaintitaniumalloys.Strainrateandtemperaturesensitivematerials(magnesium,highlyalloyednickelbasedsuperalloys,refractoryalloysandsometitaniumalloys)mayrequiremoresophisticatedforgingprocessesand/orspecialequipmentforforginginimpressiondies.

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ColdForgingMostforgingisdoneashotwork,attemperaturesupto2300degreesF,however,avariationofimpressiondieforgingiscoldforging.Coldforgingencompassesmanyprocessesbending,colddrawing,coldheading,coining,extrusionsandmore,toyieldadiverserangeofpartshapes.Thetemperatureofmetalsbeingcoldforgedmayrangefromroomtemperaturetoseveralhundreddegrees.

ProcessOperationsGraphicaldepictionofprocesssteps.

ProcessCapabilities

Coldforgingencompassesmanyprocessesbending,colddrawing,coldheading,coining,extrusion,punching,threadrollingandmoretoyieldadiverserangeofpartshapes.Theseincludevariousshaftlikecomponents,cupshapedgeometry's,hollowpartswithstemsandshafts,allkindsofupset(headed)andbentconfigurations,aswellascombinations.

Mostrecently,partswithradialflowlikeroundconfigurationswithcenterflanges,rectangularparts,andnonaxisymmetricpartswith3and6foldsymmetryhavebeenproducedbywarmextrusion.Withcoldforgingofsteelrod,wire,orbar,shaftlikepartswith3planebendsandheadeddesignfeaturesarenotuncommon.

Typicalpartsaremostcosteffectiveintherangeof10lbs.orlesssymmetricalpartsupto7lbs.readilylendthemselvestoautomatedprocessing.Materialoptionsrangeformloweralloyandcarbonsteelsto300and400seriesstainless,selectedaluminumalloys,brassandbronze.

Therearetimeswhenwarmforgingpracticesareselectedovercoldforgingespeciallyforhighercarbongradesofsteelorwhereinprocessannealscanbeeliminated.

Oftenchosenforintegraldesignfeaturessuchasbuiltinflangesandbosses,coldforgingsarefrequentlyusedinautomotivesteeringandsuspensionparts,antilockbrakingsystems,hardware,defensecomponents,andotherapplicationswherehighstrength,closetolerancesandvolumeproductionmakethemaneconomicalchoice.

Intheprocess,achemicallylubricatedbarslugisforcedintoacloseddieunderextremepressure.Theunheatedmetalthusflowsintothedesiredshape.Asshown,forwardextrusioninvolvessteelflowinthedirectionoftheramforce.Itisusedwhenthediameterofthebaristobedecreasedandthelengthincreased.Backwardextrusion,wherethemetalflowsoppositetotheramforce,generateshollowparts.Inupsetting,themetalflowsatrightanglestotheramforce,increasingdiameterandreducinglength.

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OpenDieForgingOpendieforgingisperformedbetweenflatdieswithnoprecutprofilesisthedies.Movementoftheworkpieceisthekeytothismethod.Largerpartsover200,000lbs.and80feetinlengthcanbehammeredorpressedintoshapethisway.


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ProcessCapabilities

Opendieforgingcanproduceforgingsfromafewpoundsuptomorethan150tons.Calledopendiebecausethemetalisnotconfinedlaterallybyimpressiondiesduringforging,thisprocessprogressivelyworksthestartingstockintothedesiredshape,mostcommonlybetweenflatfaceddies.Inpractice,opendieforgingcomprisesmanyprocessvariations,permittinganextremelybroadrangeofshapesandsizestobeproduced.Infact,whendesigncriteriadictateoptimumstructuralintegrityforahugemetalcomponent,thesheersizecapabilityofopendieforgingmakesittheclearprocesschoiceovernonforgingalternatives.Atthehighendofthesizerange,opendieforgingsarelimitedonlybythesizeofthestartingstock,namely,thelargestingotthatcanbecast.

Practicallyallforgeableferrousandnonferrousalloyscanbeopendieforged,includingsomeexoticmaterialslikeagehardeningsuperalloysandcorrosionresistantrefractoryalloys.

Opendieshapecapabilityisindeedwideinlatitude.Inadditiontoround,square,rectangular,hexagonalbarsandotherbasicshapes,opendieprocessescanproduce:

Stepshaftssolidshafts(spindlesorrotors)whosediameterincreasesordecreases(stepsdown)atmultiplelocationsalongthelongitudinalaxis.Hollowscylindricalinshape,usuallywithlengthmuchgreaterthanthediameterofthepart.Length,wallthickness,IDandODcanbevariedasneeded.Ringlikepartscanresemblewashersorapproachhollowcylindersinshape,dependingontheheight/wallthicknessratio.Contourformedmetalshellslikepressurevessels,whichmayincorporateextrudednozzlesandotherdesignfeatures.

Notunlikesuccessiveforgingoperationsinasequenceofdies,multipleopendieforgingoperationscanbecombinedtoproducetherequiredshape.Atthesametime,theseforgingmethodscanbetailoredtoattaintheproperamountoftotaldeformationandoptimumgrainflowstructure,therebymaximizingpropertyenhancementandultimateperformanceforaparticularapplication.Forginganintegralgearblankandhub,forexample,mayentailmultipledrawingorsolidforgingoperations,thenupsetting.Similarly,blanksforringsmaybepreparedbyupsettinganingot,thenpiercingthecenter,priortoforgingthering.

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SeamlessRolledRingForgingSeamlessrolledringforgingistypicallyperformedbypunchingaholeinathick,roundpieceofmetal(creatingadonutshape),andthenrollingandsqueezing(orinsomecases,pounding)thedonutintoathinring.Ringdiameterscanbeanywherefromafewinchesto30feet.


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ProcessCapabilities

Ringsforgedbytheseamlessringrollingprocesscanweigh

Download - Types of Forging Processes _ Forging Industry Association

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