Hammers

Widely used type of equipment for forging

the least expensive and most flexible type of forging equipment in the variety of forging operations
they can perform
Components of a hammer are a ram, frame assembly, anvil, and anvil cap.

Mechanical Presses
All mechanical presses employ flywheel energy, which is transferred to the workpiece by a network
of gears, cracks, eccentrics, or levers. Driven by an electric motor and controlled by means of an air
clutch, mechanical presses have a full eccentric type of drive shaft that imparts a constant-length
stroke to a vertically operating ram.

The ram stroke is shorter than that of a forging hammer or a hydraulic press.
Ram speed is greatest at the center of the stroke, but force is greatest at the bottom of the stroke

Types of hammers: I- Gravity drop hammers:

a- Board-drop hammers:
the ram is lifted by one or more boards keyed to it and passing between two friction rolls at the top of
the hammer. The boards are rolled upward and are then mechanically released, permitting the ram to
drop from the desired height

b- The air-lift gravity-drop hammer: It differs in that the ram in the air-lift hammer is raised by
air or steam power.

c- Electrohydraulic Gravity-Drop Hammers: In this type of hammer, the ram is lifted with oil
pressure against an air cushion. The compressed air slows the upstroke of the ram and contributes to
its acceleration during the downstroke blow

Power-Drop Hammers:
the ram is accelerated during the downstroke by air, steam, or hydraulic pressure. This equipment is
used almost exclusively for closed-die (impression-die) forging.

Die Forger Hammers

Die forger hammers are similar in operation to power-drop hammers, but have shorter strokes and
more rapid striking rates

Counterblow Hammers
The counterblow hammer, another variation of the power-drop hammer, is widely used in Europe.
These hammers develop striking force by the movement of two rams, simultaneously approaching
from opposite directions and meeting at a midway point

Differences between power-drop hammers used for closed-die forging and those used for open-
die forging:

In hammers for closed-die forging, the hammer stroke is limited by the upper die surface contacting
the surface of the lower die face. In open-die forging, the upper and lower dies do not make contact;
stroke-position control is provided through control of the air or steam valve that actuates the hammer
piston.
The anvil of an open-die hammer is separate and independent of the hammer frame that contains the
striking ram and the top die.
 Mechanisms of mech. Press:
1- Pitman arm mech. (crank shaft & con rod )
2- Scotch yoke mech. (cam press)
3- eccentric
4- Knuckle drive
5- Toggle drive

Advantages and Limitations of mech. Press:

Advantages:
1- Accurate close-tolerance parts
2- Permit automatic feed and transfer mechanisms to feed, pick up, and move the part from one die to
the next
3- Have higher production rates than forging hammers (stroke rates vary from 30 to 100 strokes per
minute)
4- Harder die materials can be used in order to extend die life, because the dies used with mechanical
presses are subject to squeezing forces. And can also be less massive in mechanical press forging.

Limits:

1- High initial cost--approximately three times as much as forging hammers

2- Mechanical presses are also not capable of performing as many preliminary operations as hammers,
because the force of the stroke cannot be varied.

Hydraulic Presses
Hydraulic presses are used for both open- and closed-die forging. The ram of a hydraulic press is
driven by hydraulic cylinders and pistons, which are part of a high-pressure hydraulic or
hydropneumatic system. After a rapid approach speed, the ram (with upper die attached) moves at a
slow speed while exerting a squeezing force on the work metal.
Pressing speeds can be accurately controlled to permit control of metal-flow velocities; this is
particularly advantageous in producing close-tolerance forging

Advantages and Limitations:

Advantages:
Pressure can be changed as desired at any point in the stroke by adjusting the pressure
control valve
Deformation rate can be controlled or varied during the stroke if required. This is especially
important when forging metals that are susceptible to rupture at high deformation rates
Split dies can be used to make parts with such features as offset flanges, projections, and
backdraft, which would be difficult or impossible to incorporate into hammer forgings
When excessive heat transfer from the hot workpiece to the dies is not a problem or can be
eliminated, the gentle squeezing action of a hydraulic press results in lower maintenance
costs and increased die life because of less shock as compared to other types of forging
equipment
Maximum press force can be limited to protect tooling

Disadvantages:
  The initial cost of a hydraulic press is higher than that of an equivalent mechanical
press
 The action of a hydraulic press is slower than that of a mechanical press
 The slower action of a hydraulic press increases contact time between the dies and the
workpiece. When forging materials at high temperatures, this results in shortened die
life because of heat transfer from the hot work metal to the dies

Types of frames in presses and hammers:

1- C-frame
2- Arch frame
3- 4 Pillar frame
4- Adjustable frame ( can be inclined)
5- Adjustable bed
6- Straight sided press

Screw Presses
Screw presses are energy-restricted machines, and they use energy stored in a flywheel to provide the
force for forging.
The rotating energy of inertia of the flywheel is converted to linear motion by a threaded screw
attached to the flywheel on one end and to the ram on the other end

Advantages and Limitations

Advantages:
1- They usually have more energy available per stroke than mechanical presses with similar
tonnage ratings, permitting them to accomplish more work per stroke
2- 2-When the energy has been dissipated, the ram comes to a halt. Stopping the ram permits
multiple blows to be made to the workpiece in the same die impression.

3- Die height adjustment is easy.

Limitations:
Impact speed is much greater than with mechanical presses

Point Press Hammer

Type of load Steady load Impact load
capacity Force produced by machine (powered) Weight of the moving part
Speed Slow deformation Fast deformation
Effect of height of w.p Doesn’t affect w.p Affect the force
Force and ram travel Force almost fixed at ram displacement Force variable with ram travel
Drift Low drift High drift
types
vibration Low vibration and noise High vibration and noise