Term Paper presentation

Topics - Forging, Classification, Calculation of forging loads,

Friction and lubrication

Members: Subject: Mechanical metallurgy

Ajay Anand Prof: Dr. Avanish Kumar
Anurag Kumar Date: 22/04/2024
Bhanu Jayanth B
Saumya Kumar
Ravi Mudavath
Maneesh Dharavath
Introduction
Definition of Forging: Forging is a
manufacturing process where metal is
shaped by applying compressive forces
using various tools and equipment.

Importance in Metallurgy: Forging plays a

crucial role in producing strong, durable,
and high-quality metal components used in
various industries.
Image: Steel Forging in ancient time
Some Facts About Forging
Forging is the working of metal into a useful shape by hammering or pressing.

The oldest of of the metalworking arts (primitive blacksmith).

Replacement of machinery occurred during the Industrial revolution.

Modern forging machines are capable of making parts ranging in size of a bolt to a
turbine rotor.

Most forging operations are carried out hot, although certain metals can be
cold-forged.
Classification
. Based on Temperature:

● Hot Forging: The most common type. Metal is heated above its recrystallization temperature (typically
around 60% of its melting point) to make it more malleable and easier to shape. This allows for complex
shapes and good grain flow in the finished product.
● Warm Forging: Metal is heated to a temperature between 30% and 50% of its recrystallization
temperature. Offers a balance between formability and strength compared to hot forging.
● Cold Forging: Metal is shaped at room temperature or slightly above. Suited for simpler shapes and
stronger, work-hardened parts, but can lead to higher tooling stress.

2. Based on Equipment:

● Press Forging: Uses hydraulic or mechanical presses to apply continuous squeezing force on the metal.
Offers good control and is suitable for complex shapes and large workpieces.
● Hammer Forging: Employs a hammer to deliver a high-impact blow to shape the metal. Faster than press
forging but less precise. Typically used with open dies for simpler shapes and smaller parts.
. Based on Workpiece Shape:

● Open Die Forging: The metal workpiece is shaped between flat or simple shaped dies. Offers flexibility for
one-of-a-kind pieces and large workpieces but requires a skilled operator.
● Closed Die Forging (Impression Die Forging): Two or more precisely machined dies completely enclose
the metal, forming a cavity that shapes the metal. Produces high-volume, near net shape parts with good
accuracy and repeatability.
● Special Forging Processes: Include variations like roll forging (using rollers to shape the metal), ring
rolling (creating seamless rings), and isothermal forging
Calculation of Forging Loads
Definition and Importance: Forging load is the force required to shape metal during the forging process.

Factors Affecting Forging Load: Material properties, deformation rate, workpiece geometry, friction, etc.

Simple Estimation:

This offers a quick approach but neglects factors like friction and strain hardening.

● Formula: F = σ_f * A
○ F: Forging Load (Force)
○ σ_f: Flow Stress of Material at Forging Temperature (MPa or ksi)
○ A: Projected Area of Forging in Contact with Die (mm^2 or in^2)

Estimation with Friction Factor:

This refines the simple estimate by incorporating friction.

● Formula: F = σ_f * A * (1 + fμ)

○ f: Friction Factor (unitless, typically between 0.1 and 0.5 depending on lubrication)
○ μ: Friction Coefficient between Die and Material (unitless)
Friction in Forging

Friction is a drag in forging!

It acts between the metal workpiece and the die, resisting the metal flow and
causing problems like:

Higher forces:
Uneven flow:
Tool wear:

To minimize friction, we use lubricants, smooth die surfaces, and optimized forging
parameters like temperature and speed.
Lubrication in Forging
Importance: Lubrication reduces friction, wear, and tool damage during the
forging process.
Types of Lubricants: Solid lubricants (graphite), liquid lubricants (oil), semi-solid
lubricants (grease).
Application Methods: Spray, immersion, brush, roller, etc.
Advantages of Forging
Forged parts have a number of advantages over parts made from other processes:
● Stronger: Forging improves the grain structure of the metal, making it stronger and
more resistant to fatigue.
● More durable: Forged parts are more durable than cast or machined parts because
they have fewer internal defects.
● Better surface finish: Forged parts can have a smooth surface finish, which can reduce
friction and wear.
● Can be produced in a wide variety of shapes and sizes: Forging can be used to create
parts of all shapes and sizes, from simple to complex
Disadvantages of Forging
Forging also has some disadvantages:
● High cost: Forging is a labor-intensive process, which can make it expensive.
● Slow production: Forging is a slow process, especially for complex shapes.
● Material waste: Forging can generate a significant amount of scrap metal.
● Requires skilled labor: Forging requires skilled labor to operate the forging machines and dies.
Forging Defects
In general, defects in parts manufactured by metal forging can be controlled
first by careful consideration of work stock volume, and by good design of the
forging die (mold).

The main principle is to enact the right material distributions, and the right
material flow to accomplish these distributions.
Applications of Forging
● High Strength and Durability: Crankshafts, connecting rods, landing gear, drill bits
● Fatigue Resistance: Gears, shafts, turbine blades
● Formability for Complex Shapes: Engine discs, wing spars, surgical instruments
● Variety of Sizes: Crankshafts (large) to wrenches (small)
Conclusion
● Forging is a versatile metalworking process that has been around for
centuries.
● It is a powerful tool that can be used to create a wide variety of products, from
simple tools to complex components for airplanes.
● Forger parts offer several advantages over parts made from other processes
including superior strength, durability and surface finish.
● While there are some disadvantages to consider, such as cost and production
speed, forging still remains an important process in the manufacturing
industry.
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