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L03 Forging ENIM 2024-25

The document is a lecture on forging technology, covering topics such as open-die and closed-die forging, process temperatures, and tool design. It highlights the advantages of forging, including improved material utilization and product quality. Additionally, it discusses various forging processes, their mechanics, and applications in manufacturing.

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Mediouni Chaima
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We take content rights seriously. If you suspect this is your content, claim it here.
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0% found this document useful (0 votes)
7 views30 pages

L03 Forging ENIM 2024-25

The document is a lecture on forging technology, covering topics such as open-die and closed-die forging, process temperatures, and tool design. It highlights the advantages of forging, including improved material utilization and product quality. Additionally, it discusses various forging processes, their mechanics, and applications in manufacturing.

Uploaded by

Mediouni Chaima
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
Available Formats
Download as PDF, TXT or read online on Scribd
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Module SM1: Forming Technology

Part SM1-2: Bulk Forming

Lecture 03: Forging

2024-25

Prof. Dr.-Ing. habil. Sami Chatti

Content

L03 – Forging

Introduction

Open-die forging
Upsetting
Drawing out

Closed-die forging (Drop forging)

Process temperature and tool design

2024-25 Sami Chatti BF L03 – Forging 3.1

1
Content

L03 – Forging

Introduction

Open-die forging
Upsetting
Drawing out

Closed-die forging (Drop forging)

Process temperature and tool design

2024-25 Sami Chatti BF L03 – Forging 3.2

Forging - advantages

Advantages of a forging process: Advantages of forged products:

High utilisation of material Improved microstructure


High productivity High fatigue strength and ductility
High stability of the process Better surface quality in comparison
to cast products
Beneficial grain flow (fibers)

2024-25 Sami Chatti BF L03 – Forging 3.3

2
Forged parts

( Deutsche Schmiedetechnik )

2024-25 Sami Chatti BF L03 – Forging 3.4

Forging - film

Source: Deutsche Massivumformung


2024-25 Sami Chatti BF L03 – Forging 3.5

3
Forged parts in a jet engine
(Picture: Pratt & Whitney)
Front fan blades
Low pressure compressor blades

High pressure compressor blades


Turbine shaft

Turbine disks

Source: W. Adolf „Schmiedeteile Gestaltung, Anwendung, Beispiele“


2024-25 Sami Chatti BF L03 – Forging 3.6

Forgeable materials

Group of steels Standards


Mild steel DIN EN 10025

Heat-treatable steel DIN EN 10083

Nitriding steel DIN 17211

Steel for pressure purpose DIN EN 10028

Roll bearing steel DIN 17230/40

High-temperture steel DIN 17243

Stainless steel DIN EN 10088


Bright steel products DIN EN 10277

Source: Deutsche Schmiedetechnik We_0200_pta


2024-25 Sami Chatti BF L03 – Forging 3.7

4
Forging temperatures

Hot forging

Process temperature
Warm forging

Cold forging

Source:
Isothermal forging

Source: Kalpakjian
2024-25 Sami Chatti BF L03 – Forging 3.8

Comparison: Hot forging / Cold forging

Hot forging Cold forging

• Production of single parts • Production of single parts


• Greater technical and economical • Process consists of: forging,
importance upsetting, coining
• Low stresses • High stresses
• No / low strain hardening • Strain hardening
• Homogenous microstructure • High die loads
• High formability • Limited formability
• Medium up to low geometrical • Parts are near-net-shaped or net
accuracy shape (high geometrical accuracy)
• Scale formation • High surface quality
• Forging temperatures:
– Steel: > 1000°C (up to 1250°C)
– Al-alloys: 360°C - 520°C
– Cu-alloys: 700°C - 800°C

2024-25 Sami Chatti BF L03 – Forging 3.9

5
Forging Procedures

Open die forging Drop forging

Upper die

Upper die

Workpiece

Lower die

Lower die

Workpiece

2024-25 Sami Chatti BF L03 – Forging 3.10

10

Comparison:
Open-die forging / Closed-die forging
Open-die forging Closed-die forging
• Definition: Suitable for large • Definition: Suitable for smaller
products products
• Aim: To achieve a convenient • Aim: Achieve best possible
mass distribution or shape for the dimensional accuracy and
successive operations mechanical properties of the
(machining or closed-die forging) product
• Simple tools, which geometry do
not depend on the product • Tools which geometry is product
geometry dependent
Upper die
Upper die
Workpiece
Lower die

Workpiece

Lower die
2024-25 Sami Chatti BF L03 – Forging 3.11

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6
Content

L03 – Forging

Introduction

Open-die forging
Upsetting
Drawing out

Closed-die forging (Drop forging)

Process temperature and tool design

2024-25 Sami Chatti BF L03 – Forging 3.12

12

Film: Open die forging

Source: youtube
2024-25 Sami Chatti BF L03 – Forging 3.13

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7
Classification of the forming processes open-die
forming according to DIN 8583-3

Open-die forming

Spread Expanding
Drawing Hammer-
Swaging Upsetting by Sweeping
out forging ing
hammering

2024-25 Sami Chatti BF L03 – Forging 3.14

14

Achievable changes in cross-section of open


die forging processes

• Drawing out (material displacement, mainly in longitudinal direction)


• Spread forging (material displacement, mainly in width direction)
• Upsetting (material compression)

Open-die forging processes Change in cross-section


Drawing out, Spread forging A0 /A1 >> 4-5
Upsetting A1 /A0 < 4-5

2024-25 Sami Chatti BF L03 – Forging 3.15

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8
Process principle of open die forging

Process principle: Process steps:


Upper die
Heating

Descaling

Work- Forging
piece
Further processing

Lower die Mechanically

By quenching

Flat die Tapered die Round die


2024-25
Foto: ISV Sami Chatti BF L03 – Forging 3.16

16

Process principle of open die forging

Process principle: Process steps:


Upper die
Heating

Descaling

Work- Forging
piece
Further processing

Lower die Mechanically

By quenching

Milling

Grinding

Flat die Tapered die Round die Turning


2024-25
Film: ISV (www.schmiede-info.de) Sami Chatti BF L03 – Forging 3.17

17

9
Partially forged crankshaft

2024-25 Sami Chatti BF L03 – Forging 3.18

18

Film: Open die forging – Manufacturing of a


generator shaft

Source: youtube
2024-25 Sami Chatti BF L03 – Forging 3.19

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10
Content

L03 – Forging

Introduction

Open-die forging
Upsetting
Drawing out

Closed-die forging (Drop forging)

Process temperature and tool design

2024-25 Sami Chatti BF L03 – Forging 3.20

20

Principle of upsetting

Initial state Finished shape Example of manufacturing:


Cylinder compression Pre- and finish upsetting of
F a bolt

l0
l1

d0 d1

Ring compression
F

l0
l1

di0 di1 Semi-finished Pre- Finished


product upsetting upsetting
do0 do1 (Rod/bar) Source: Geiger
2024-25 Sami Chatti BF L03 – Forging 3.21

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11
Upsetting animation

Source: youtube
2024-25 Sami Chatti BF L03 – Forging 3.22

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Film: Open die forging – Upsetting

Source: youtube
2024-25 Sami Chatti BF L03 – Forging 3.23

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12
Process parameters of upsetting

 l0 
Equivalent strain   ln  
(true strain):
l 
l0
Upsetting ratio: s
d0

l
Relative reduction
of height:
e
l0

d vWerkzeug
Equivalent strain rate:
   Tool
dt ll
2024-25 Sami Chatti BF L03 – Forging 3.24

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Mechanics of upsetting: stresses

The slab model provides the following stresses:

For the Coulomb friction


 2  D 
 r    2  D 
model and the yield
 r  r      r    kf  e l 2 
 1   kf    r  
criterion by Tresca:    l 2 
    
nach Taylor's Reihenentwicklung
By Taylor series

2  D 
 r   2  D 
 z  r    kf e l 2 
  kf 1    r 
 l 2 
  
nach Taylor's Reihenentwicklung
By Taylor series

For the shear friction m D r 


model and the yield  r  r      r    kf 1  
criterion by v. Mises : l
3  D /2
 m D r 
 z  r   kf 1  1  
 3 l  D / 2 
2024-25 Sami Chatti BF L03 – Forging 3.25

25

13
Normal stress course of upsetting

Friction free upsetting: Upsetting with friction Upsetting with friction


(linear approximation): (exponential function):
z z z
kf kf kf
 σr=σθ
σr=0 σr=r σθ
σθ=0

l l l

 2  D   2  D 
 z   kf  z  kf 1    r   z   kf e
 r 
l 2 

Source: Lange  l 2 
2024-25 Sami Chatti BF L03 – Forging 3.26

26

Upsetting: force & work

Forming force: Fz     z dA
A

  1 D
Fz  D 2  kf  1     
4  3 l 

s
Forming work: W   Fz ds in which s is the punch stroke.

2024-25 Sami Chatti BF L03 – Forging 3.27

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14
Cold aluminium upsetting simulation

2024-25 Sami Chatti BF L03 – Forging 3.28

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Example 1: Cylinder upsetting

During a frictionless upsetting test at room temperature (T0 = 20 °C) , a cylindrical


specimen with an initial radius of r0 = 20 mm and an initial height of h0 = 40 mm
shows a height reduction of 10 %. The flow stress of the material can be
approximated by 𝑘 = 547 MPa 0.005 + φ . .

a) Calculate the radius r1 after the deformation.

b) Calculate the maximum required Force Fmax at the end of forming.

2024-25 Sami Chatti BF L03 – Forging 3.29

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15
Example 1: Cylinder upsetting

2024-25 Sami Chatti BF L03 – Forging 3.30

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Forming limit diagram for cold upsetting of steel


Tool failure limit Limit for the formability of the material

.
. . l .
Relative change in length

.
e = Δl/l0

.
.

.
Buckling limit

𝑙 −𝑙
𝑒 =
𝑙 Upsetting ratio s = l0/D0
𝑙
𝜑 = ln Upsetting in Upsetting in Upsetting in
𝑙 one step two steps several steps
Source: Lange
2024-25 Sami Chatti BF L03 – Forging 3.31

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16
Upsetting

2024-25 Sami Chatti BF L03 – Forging 3.32

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Manufacturing of upsetted parts


Cold upsetting
Example 1 Example 2

 
True upset strain: s 7 True upset strain: s  12
d d

l
l

d d

1 2 3 1 2 3 4 5
Three upsetting steps are necessary Five upsetting steps are necessary

Source: VDI 3171 Richtlinien zum Stauchen


2024-25 Sami Chatti BF L03 – Forging 3.33

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17
Examples of cold upsetting

Bolt

Source: Norm Civata Rivet


2024-25 Sami Chatti BF L03 – Forging 3.34

34

Coining

Coining is an upsetting process of thin parts, the reduction


of height is low but the forming force is high.

Upper die

Closing ring
Workpiece Tool holder

Tool holder Workpiece


Lower die

Tool rough Flat die


vacuum

Source: Kalpakjian
2024-25 Sami Chatti BF L03 – Forging 3.35

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18
Video: Denver MINT Coin Production

Source: https://www.youtube.com/watch?v=MVXC9P7rMwk
2024-25 Sami Chatti BF L03 – Forging 3.36

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Orbital forging I

1 Lower die
2 Workpiece
3 Ejector • •
4 Upper die
Rotary movement Spiral movement
5 Plunger
6 Pressing frame
7 Plunger guide

Pendular Several blade


movement movements
in a plane

Source: Schmid
2024-25 Sami Chatti BF L03 – Forging 3.37

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19
Orbital forging II

Video

Prof. Marciniak

Orbital forged pieces

2024-25 Sami Chatti BF L03 – Forging 3.38

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Film: Orbital forging for forming rivets

Source: youtube
2024-25 Sami Chatti BF L03 – Forging 3.39

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20
Orbital forging
comparison to upsetting

Upsetting between flat Orbital forging


tool plates
Normal stress

Normal stress
z max
σ zmax
kf kf

s
Ød s Ød
Area of contact Reduced area
of contact

Source: Marciniak
2024-25 Sami Chatti BF L03 – Forging 3.40

40

Content

L03 – Forging

Introduction

Open-die forging
Upsetting
Drawing out

Closed-die forging (Drop forging)

Process temperature and tool design

2024-25 Sami Chatti BF L03 – Forging 3.41

41

21
Process variables of drawing out

F
Relative decrease of height  w0
h0 – h1
=
h0
Upper die
h0
Drawing out ratio 
w0 h0 l1 sB
= =
w1 h1 l0
b
Spreading ratio 
w1 h1
=
w0
w1
Lower die
Bite ratio sB / h0
Workpiece

2024-25 Sami Chatti BF L03 – Forging 3.42

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Video: drawing out

2024-25 Sami Chatti BF L03 – Forging 3.43

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22
Content

L03 – Forging

Introduction

Open-die forging
Upsetting
Drawing out

Closed-die forging (Drop forging)

Process temperature and tool design

2024-25 Sami Chatti BF L03 – Forging 3.44

44

Film: Closed die forging (Drop forging)

Source: youtube
2024-25 Sami Chatti BF L03 – Forging 3.45

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23
Classification of the forming processes closed-die
forming according to DIN 8583-4
Closed-die
forming

Closed-die forming with Closed-die forming with


partially enclosed work piece completely enclosed work piece

...

Upsetting in Radial Closing in


Fullering Gathering
an open die forging the die

2024-25 Sami Chatti BF L03 – Forging 3.46

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Film: Closed die forging with partially enclosed


workpiece

Source: youtube
2024-25 Sami Chatti BF L03 – Forging 3.47

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24
Classification of the forming processes closed-die
forming according to DIN 8583-4
Closed-die
forming

Closed-die forming with Closed-die forming with


partially enclosed work piece completely enclosed work piece

...

Partial upsetting Impression Flashless upsetting in an


in a closed-die die forging die forging impression die

2024-25 Sami Chatti BF L03 – Forging 3.48

48

Material flow in closed-die forging

1) Insertion of the blank 2) Spread forging, 3) Rising (upward flow),


the material flows primarily the material flows primarily
in the width direction in the direciton of the
force axis

4) Flash formation 5) Excess material is 6) Finish forging


discharged from the cavity
through the die land

2024-25 Sami Chatti BF L03 – Forging 3.49

49

25
Process principle of closed-die forging and
process characteristics
3 Main stages of closed-die forging Process characteristics:
Tool Material
Advantages of closed-die
movement flow
Spread forging forging:
- Suitable for automation
Rising (upward flow) - High productivity (in case of
small parts number of strokes
up to 100/min)
Finish forging - Serial production
- Good dimensional accuracy
Finish forging (precision forging possible:
Spread forging ready to install)
Force Disadvantages:
Rising High costs for tools (dies),
energy and total investment
(press)

Rising
Fields:
Production of engieered
Spread forging components in serial and high
volume production (i.e. safety
components: knuckles,
chassis...)
Displacement
Finish forging
2024-25 Sami Chatti BF L03 – Forging 3.50

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Hot closed-die forging of AlMgSi

2024-25 Sami Chatti BF L03 – Forging 3.51

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26
Content

L03 – Forging

Introduction

Open-die forging
Upsetting
Drawing out

Closed-die forging (Drop forging)

Process temperature and tool design

2024-25 Sami Chatti BF L03 – Forging 3.52

52

Process variables of closed-die forging

Slug
Tool Tool Forging
Dwell time temperature
velocity temperature geometry
distribution

Temp. dis-
Forming Workpiece tribution during Lubricant
speed material forming process

Flow Friction
stress conditions

Necessary
forging force
and work

2024-25 Sami Chatti BF L03 – Forging 3.53

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27
Hot forging temperature

Workpiece temperature

Lower limit Upper limit


• Higher than the • Oxidation or melting of the
recrystallisation temperature impurities at the grain boundaries
• Grain growth (overheating)
• Increased scale formation and
decarburisation
• Tendency of fracture on the blank
surface

Workpiece temperature is neither constant in time nor in space


Temperature decrease due to radiation and conduction
Temperature increase due to friction and deformation heat
2024-25 Sami Chatti BF L03 – Forging 3.54

54

Typical hot flow curves for C45

400
  40 s 1
T = 800oC 8 s 1
in MPa

300
MPa


1.6 s 1
kf in

40 s 1
stress

200
Flowstress

T = 1000oC 8 s 1

1.6 s 1
Flow

100

T = 1200oC 40 s 1 8 s 1 1.6 s 1
0
0 0,2
0.2 0,4
0.4 0,6
0.6 0,8
0.8 1 1,2
1.2
Equivalent plastic strain φ
Source: MSC/AutoForge
2024-25 Sami Chatti BF L03 – Forging 3.55

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28
Forging press characteristics

Forging Impact speed Dwell


press of the tool time

High-speed hammer ~ 16 m/s 0.5 – 5 ms

Die-forging hammer ~ 6 m/s 1 – 10 ms

Crank press ~ 1 m/s 20 – 100 ms

Friction screw press ~ 0.5 m/s 50 – 150 ms

Hydraulic press ~ 0.1 m/s 250 – 500 ms

Source: Lange
2024-25 Sami Chatti BF L03 – Forging 3.56

56

Failures of forging dies

Wear

Thermal fatigue

Mechanical fatigue

Plastic deformation

Source: Kannappan
2024-25 Sami Chatti BF L03 – Forging 3.57

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29
Film: Forgings – Manufacturing and Application

2024-25 Sami Chatti BF L03 – Forging 3.58

58

Appendix: English for Production Engineers

English Français English Français


Forging Forgeage Drawing out Etirage
Open-die Spread forging Ecrasement latéral
forging Forgeage libre
Closed-die Forgeage par Flash Bavure
forging estampage
Impression die
Matriçage Crankshaft Vilebrequin
forging
Vitesse de
Descaling Décapage Strain rate
déformation
Cold forging Forgeage à froid Die Matrice
Forgeage à mi-
Warm forging chaud Upward flow Montée du métal
Hot forging Forgeage à chaud Fiber course Fibrage
Upsetting Refoulement Fracture Rupture
Coining Frappe Wear Usure
2024-25 Sami Chatti BF L03 – Forging 3.59

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