FORGING DIE DESIGN CALCULATIONS

1. Forging force: -

p=2bwk[1+b/4t2]

Where b=width of die,

w=width of work,
k=shear flow stress.

2k[1+b/4t2] = Average pressure under the dies

t1 = Thickness of the work before forging
t2 = Thickness of the work after forging

Hint:- w/t1 = not more than 1.5

t1/b = less than 3

2. Width to thickness ratio of forgings :-

= 3:1 to 5:1
3. TO calculate blank size :-

W1 = W+Losses
where,
W1 = weight of stock
W = Net weight of forging
Shear loss = 6% of net weight (W)
Sprue loss = 7% - 8% of net weight
Scale loss = 6% of w
4. Length of stock :-

Length of the stock, (L) = W/f*A

Where,
f = Density of metal
A=Largest cross-section area

5.Draft angles :-
Alpha = Draft angle for outside faces
= 50 - 70
Beta = Draft angle for inside faces
= 70 - 100
6. Minimum section size :-

T = Web thickness = 1/8 x B

Where,
B = Web width
h = height of the rib or web = 4 B – 6 B
7. Mismatch (S) :-
S = 0.3 mm for forging upto 5 kg weight
= 0.5 mm for forgings from 5 – 10 kg weight

8. Tolerances and thickness:-

1 mm on forgings up to 1 kg weight
2 mm on forgings up to 2 – 10 kg weight

Negative tolerances on thickness

0.12 mm up to 1 kg weight
0.5 mm from 2 – 10 kg weight
0.8 mm from 10 – 20 kg weight

Machining allowance
= 1.5 mm per side for up to 5 kg
= 1.5 – 3 mm for medium forgings
= 3 – 6 mm for large forgings
9. Holes and Cavities :-

Maximum depth of cavity (h) = d, and

h = 1.5 d if a full radius allowed at the
bottom.
Where d = Size of diameter.