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Lab+6+Forging

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Lab+6+Forging

Uploaded by

brfox2123
Copyright
© © All Rights Reserved
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Download as PDF, TXT or read online on Scribd
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ISE 2500

Forging Lab
Reading Assignment:
Groover Textbook Chapter 3.2.1 (Hardness Tests), Chapter 18, and Chapter 19.3.1
(Open Die Forging)

Learning Objectives:
Students will be able to:
 Determine the influence of cold work versus hot work in a forging/upsetting process
(design for manufacture)
 Understand the process steps, operation sequences, labor requirements, production
rate, and equipment involved in typical forging operation (process planning)
 Recognize important attributes of the raw materials, process methods, and finished
products, and identify methods for and assessing (measuring) those attributes
(problem solving and continuous improvement)

Materials & Equipment:


 OBI (Open Back Inclinable) mechanical press w/ the Helm LoadGard system
 Upset tooling, tongs/pliers, MAPP gas torch
 Specimens: 2 billets of 3/8 inch hot rolled A36 Steel
 Dial calipers
 Scleroscope Hardness tester

Procedure:
Part I – Cold Forging/Upsetting

1. Obtain one steel billet from the lab instructor.


2. Measure and record the initial dimensions of the billets (O.D. & height).
3. Measure the average hardness of the billet (two locations - flat surfaces only).
4. Set the OBI press for the first step in the upsetting process (shim 1).
5. Using tongs, insert one of the billets into the tooling. Try to place it as close to the
center of the upsetting platen as possible.
6. Step on the yellow pedal to cycle the press one time.
7. Record the press load from the LoadGard system. (Note: After recording the load,
make sure to reset the LoadGard system in order to prevent reading failure for the
next measurement.)
8. Use the tongs to remove the deformed billet.
9. Measure and record the new billet height, and measure and record the average
hardness (two locations).
10. Adjust the press for the next deformation (shims 2 through 5). Repeat steps 4-9 for
a total of five deformation steps. (Caution: The flywheel on the punch press must be
idle, which means the OBI press machine must be turned off, before changing shut
height.)
11. Mark the steel billet such that it can be identified as the cold forged sample and
keep it for comparison with the hot forged sample.
Part II – Hot Forging/Upsetting

1. Obtain a second steel billet from the lab instructor.


2. Measure and record the initial dimensions of the billets (O.D. & height).
3. Measure the average hardness of the billet (two locations - flat surfaces only).
4. Set the OBI press to forge this sample in a single hit (shim 5).
5. Heat the billet with the torch until it glows orange (approximately 1500-1600°F).
6. Forge the billet as in Part I above and record the press load. (Wait for the billet to
cool before removing it from the press.)
7. After the part is cool, measure and record the new billet height, and measure and
record the average hardness (two locations).
8. Mark the billet such that it can be identified as the hot forged sample, and keep it for
comparison with the cold forging sample.

Part I Data – Cold Forging/Upsetting

Specimen: A36 Steel, K= 100 ksi, n = 0.15, OD0 = , h0=

Hs HR30T Fmeasured hf Aavg εi Yf Ffrictionless


1
2
3
4
5
Note: Use volume consistency to calculate the average Area of the forged part.
Volume Consistency: h   r 2  h   r 2
1 1 2 2

Part II Data – Hot Forging/Upsetting

Hs HR30T Fmeasured hf Aavg εi

Lab Report Assignment:

1. Design for Manufacture


a. Present your observations of the differences between cold and hot
forging, including:
i. Required (measured) punch force
ii. Hardness of the formed billets
iii. Uniformity of deformation (barrel shape). Explain why this
occurs.
b. Why would anyone choose to hot forge? Present three distinct reasons.
2. Process Planning
a. Complete the calculations required for Parts I and II. Present observed
data and calculation results in a table or spreadsheet similar to the tables
on the lab data sheet above. Present your method, including algebraic
equations, for completing the calculations. Include one sample
calculation (ignoring friction), i.e. the first hit on the cold forged sample.
b. Discuss how the observed force data compares with the calculated force
data. If they are significantly different, explain why.
c. The Robinson is a 30 ton press. Could the cold forging have been
accomplished in fewer than 5 steps? Why or why not?
d. Consider a situation where 500 cold forged parts (identical to the one we
made in lab) need to be produced per shift (8 hours). Suggest a process
plan to accomplish this production rate, assuming that the 5 cold forging
steps (and corresponding 5 punch height set-ups) are required.
3. Problem Solving
a. What is the relationship between BHN and UTS in steels?
b. What were the approximate UTS values for the original hot rolled steel
A36 bar, the cold forged final product, and the hot forged final product?

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