FORGING

1) Explain open & closed die forging.

A strip of metal with initial dimensions
28X28X160mm is forged between two flat dies to a
final size of 7X112X160mm. If the coefficient of
friction between the job and die is 0.08. Determine
the Max. forging load. Take yield strength of the
material as 150 Mpa.
2) A strip of lead with initial dimensions
24X24X150mm is forged between two flat dies to a
final size of 6X96X150mm. If the coefficient of
friction between the job and die is 0.25. determine
the maximum forging force. The avg. yield stress of
lead in tension is 7 Mpa.
3) Explain Drop forging & Press forging
A work piece of 30 mm diameter and 40 mm height is
compressed between two platens in an open die
forging process. Assume a perfectly plastic material
with a flow stress of 300 Mpa. The ideal forging load(in
KN) at 30% reduction (in height) is--------
4) A circular disc of 200mm dia and 100mm thick is
compressed between two dies to a thickness of
50mm. Determine the Max. die pressure if µ= 0.1,
the yield strength of the material is 230 Mpa.
5) A cylindrical work piece of 100 mm diameter and
60 mm height is forged between two flat dies. Find
the die load at the end of compression to a height of
30mm, using slab method of analysis. The yield
strength of the material as 120 Mpa. Take µ= 0.05.
Assume there is no sticking. Also find mean die
pressure
7) A certain disc of lead of radius 150 mm and
thickness 50 mm is reduced to a thickness of 25mm
bye open die forging. Determine Max. forging force.
The average yield strength of the lead can be taken
as 4 Mpa. Take µ= 0.25.
8) What are the various forging defects, Explain
any five in brief.