Forging

Workshop Practice
ME-105

Department of Mechanical Engineering

College of E&ME, NUST Pakistan
 What You Will Learn
• What is forging
• Various forging techniques
• Equipment for forging
• A bit of math behind forging (analysis)
• Some simple examples
 What is Forging
• A metal forming technique used to shape
metals by application of local compressive
forces.
• Compressive forces can be generated in a
metal either through impact (with hammers)
or by gradually pressing (with presses).
• Forging is typically used to establish a
basic/initial shape of a part.
 Forging Illustrated
Drop Hammer
Forging

Press Forging

Manual Hammer Forging

 Forging and Temperature
• Metal can be shaped at both low and high
temperatures by appropriate application of
force/pressure.
• Based upon temperature forging is classified
as:
– Hot or Warm Working: Requires less
force/pressure. Increases ductility but reduces
strength
– Cold Working: Increases strength but requires
greater forces/pressure
 Dies and Types of Forging
• Dies are used to constraint the workpiece
between two or more surfaces while force is
being applied to it.
• Based on the type of die being used, forging
can be classified as:
– Open Die Forging
– Impression Die Forging
– Flashless Forging
Types of Forging Dies
 Open Die Forging

•It involves compression of a workpiece between two flat dies and is

similar to compression testing. At times the dies are not purely flat.
•Resulting deformation reduces the height but increases the cross
section of a workpiece.
•Such a deformation process is also known as upsetting or upset
forging.
•If no friction occurs between the die and workpiece under
compression, a uniform deformation occurs in which radial flow is
uniform throughout the workpiece height.
 Open Die Forging with Friction

•In the absence of a lubricant, friction between the workpiece and die
surfaces pops up.
•Due to friction between the workpiece and die surfaces, metal flow
becomes non-uniform.
•Consider the example of water flowing in a river; water flows faster in the
center and slower near the river bank.
•In hot forging, friction effects are even more pronounced.
Impression Die Forging
 Impression Die Forging
• Advantages
– Higher production rates
– Less material wastage
– Higher Strength and Strength to Weight Ratios
– Favorable grain orientation in the metal crystalline
structure
• Disadvantages
– Not capable of close tolerances
– Machining is often required to achieve the desired
level of final accuracy and features
Trimming
Flash less Forging
Flash less Forging
Upsetting and Heading
Upsetting and Heading Cont.
Swaging and Radial Forging
Forging Hammers
Forging Presses
What are the properties and uses
of mild steel
Time To Get Your
Hand’s Dirty !