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Forging
Forging
'
= x a
h
y
u
o o
2
exp
0
|
.
|
\
|
'
=
L
x
h
L
y
2
1 exp
0
u
o o
Since, L= 2a
Dr. D. Das, MME, BESU-Shibpur, 2012
Since, is a small number, we neglect higher order terms of
( ) + + + + =
! 3 ! 2
1 exp
3 2
Y Y
Y Y
( ) ( )
+
'
~
'
= x a
h
x a
h
y
u
o
u
o o
2
1
2
exp
0 0
Forging Load with friction in Plane-Strain
( )
a
a a
y
h
x
h
ax
x
a
dx x a
h a
dx
a
p
0
2
0
0 0
0
2 2
1
+
'
=
+
'
= =
u u o u o
o
|
.
|
\
|
+
'
=
h
a
p
u
o 1
0
Dr. D. Das, MME, BESU-Shibpur, 2012
Forging Load: Sticking friction
Dr. D. Das, MME, BESU-Shibpur, 2012
Forging Load: Sticking friction
( ) 0 2 = + dx h d h
xy x x x
t o o o
Taking the equilibrium of forces in the X-direction
h dx
d
xy
x
t
o
2
=
h dx
d
xy y
t o 2
=
mk
i xy
= =t t
h
dx
m
h
dx
m dx
h
mk
d
y 0
0
3
2 2
o
o
o
'
= = =
C
h
x
m
y
+
'
=
0
o o
After integration
Putting the boundary condition at x=a,
0
o o
'
=
y
( )
+
'
= x a
h
m
y
1
0
o o
Dr. D. Das, MME, BESU-Shibpur, 2012
Forging Load: Sticking friction
For Sticking friction m = 1
+
'
=
h
x a
y
1
0
o o
Under this condition mean pressure
|
.
|
\
|
+
'
=
h
a
p
2
1
0
o
Dr. D. Das, MME, BESU-Shibpur, 2012
Transition from Slipping to Sticking Friction
( )
'
= x a
h
y
u
o o
2
exp
0
Dr. D. Das, MME, BESU-Shibpur, 2012
Cost-per-piece in Forging
Dr. D. Das, MME, BESU-Shibpur, 2012
Cost Comparison
Relative unit costs of a small connecting rod made by various forging and casting processes. Note
that, for large quantities, forging is more economical. Sand casting is the most economical
process for fewer then about 20,000 pieces.
Dr. D. Das, MME, BESU-Shibpur, 2012
A pierced round billet showing grain-flow pattern
Grain Flow in Forging
Dr. D. Das, MME, BESU-Shibpur, 2012
Effect of forging on microstructure
Dr. D. Das, MME, BESU-Shibpur, 2012
Forming Texture
Dr. D. Das, MME, BESU-Shibpur, 2012
Forming Texture
Dr. D. Das, MME, BESU-Shibpur, 2012
Forming: Residual stress
Dr. D. Das, MME, BESU-Shibpur, 2012
Defects in Forged Parts
Laps formed by web buckling during forging; web thickness should be increased to
avoid this problem.
Internal defects caused by an oversized billet. Die cavities are filled prematurely, and
the material at the center flows past the filled regions as the die closes.
Dr. D. Das, MME, BESU-Shibpur, 2012
Defects in Forged Parts
Dr. D. Das, MME, BESU-Shibpur, 2012
Typical Forging Defects