1. Forging of Metals

2. Introduction A metal is shaped by compressive forces
Oldest metal working process – 4000BC
Can be performed with a hammer and anvil
Typical forged products:
Bolts
Rivets
Connecting rods
Gears

3. Steps involved in forging a bevel gear with a shaft.
Lading-gear components for the C5A and C5B transport aircraft, made by forging.
Steps involved in forging a bevel gear with a shaft.

4. Outline of Forging and Related Operations

5. Grain Structure Parts have good strength High toughness
Forgings require additional heat treating
Fig : A part made by three different procedures, showing grain flow (a) casting (b) machining (c) forging

6. Open-Die Forging Is the simplest forging process
Sizes can very from very small parts to very large parts

7. Open-Die Forging
Upsetting or flat-die forging – a solid workpiece is placed between flat dies and is compressed
Barreling
caused by frictional forces at the die-workpiece interfaces
Can be minimized if a lubricant is used
Thermal effects caused by barreling can be minimized by using heated dies

8. Open-Die Forging
Forging force

9. Impression-Die & Closed-Die Forging
The workpiece acquires the shape of the die cavities while being forged between the two shaped dies

10. Impression-Die & Closed-Die Forging
The blank to be forged is prepared by:
Cutting from a bar stock
Preformed blank
Casting
Preformed blank from prior forging

11. Impression-Die & Closed-Die Forging
Fullering & edging are used to distribute the material
Fullering – material is distributed away from an area
Edging – material is gathered into an area
Blocking – rough shaping of the part
Impression dies – give the part its final shape

12. Precision Forging Used for economic reasons
The part formed is close to the final dimensions
Less machining is needed
Higher capacity equipment is needed
Aluminum and Magnesium alloys work well in the process

13. Coining Closed-die forging process
Used for minting coins, medallions, & jewelry
Lubricants can not be used in coining
Can be used to improve surface finish

14. THE END