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Forging of Metals

Forging of Metals. Chapter 14. Introduction . A metal is shaped by compressive forces Oldest metal working process – 4000BC Can be performed with a hammer and anvil Typical forged products: Bolts Rivets Connecting rods Gears.

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Forging of Metals

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  1. Forging of Metals Chapter 14

  2. Introduction • A metal is shaped by compressive forces • Oldest metal working process – 4000BC • Can be performed with a hammer and anvil • Typical forged products: • Bolts • Rivets • Connecting rods • Gears

  3. Lading-gear components for the C5A and C5B transport aircraft, made by forging. Steps involved in forging a bevel gear with a shaft.

  4. Outline of Forging and Related Operations

  5. Parts have good strength High toughness Forgings require additional heat treating Fig : A part made by three different procedures, showing grain flow (a) casting (b) machining (c) forging Grain Structure

  6. Open-Die Forging • Is the simplest forging process • Sizes can very from very small parts to very large parts

  7. Open-Die Forging • Upsetting or flat-die forging–a solid workpiece is placed between flat dies and is compressed • Barreling • caused by frictional forces at the die-workpiece interfaces • Can be minimized if a lubricant is used • Thermal effects caused by barreling can be minimized by using heated dies

  8. Open-Die Forging • Forging force

  9. Impression-Die & Closed-Die Forging • The workpiece acquires the shape of the die cavities while being forged between the two shaped dies

  10. Impression-Die & Closed-Die Forging • The blank to be forged is prepared by: • Cutting from a bar stock • Preformed blank • Casting • Preformed blank from prior forging

  11. Impression-Die & Closed-Die Forging • Fullering & edging are used to distribute the material • Fullering – material is distributed away from an area • Edging – material is gathered into an area • Blocking – rough shaping of the part • Impression dies – give the part its final shape

  12. Precision Forging • Used for economic reasons • The part formed is close to the final dimensions • Less machining is needed • Higher capacity equipment is needed • Aluminum and Magnesium alloys work well in the process

  13. Coining • Closed-die forging process • Used for minting coins, medallions, & jewelry • Lubricants can not be used in coining • Can be used to improve surface finish

  14. THE END

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