L03 Forging ENIM 2024-25
L03 Forging ENIM 2024-25
2024-25
Content
L03 – Forging
Introduction
Open-die forging
Upsetting
Drawing out
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Content
L03 – Forging
Introduction
Open-die forging
Upsetting
Drawing out
Forging - advantages
2
Forged parts
( Deutsche Schmiedetechnik )
Forging - film
3
Forged parts in a jet engine
(Picture: Pratt & Whitney)
Front fan blades
Low pressure compressor blades
Turbine disks
Forgeable materials
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
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Forging Procedures
Upper die
Upper die
Workpiece
Lower die
Lower die
Workpiece
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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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Content
L03 – Forging
Introduction
Open-die forging
Upsetting
Drawing out
12
Source: youtube
2024-25 Sami Chatti BF L03 – Forging 3.13
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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
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15
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Process principle of open die forging
Descaling
Work- Forging
piece
Further processing
By quenching
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Descaling
Work- Forging
piece
Further processing
By quenching
Milling
Grinding
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Partially forged crankshaft
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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
20
Principle of upsetting
l0
l1
d0 d1
Ring compression
F
l0
l1
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Upsetting animation
Source: youtube
2024-25 Sami Chatti BF L03 – Forging 3.22
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Source: youtube
2024-25 Sami Chatti BF L03 – Forging 3.23
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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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2 D
r 2 D
z r kf e l 2
kf 1 r
l 2
nach Taylor's Reihenentwicklung
By Taylor series
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Normal stress course of upsetting
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
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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.
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Cold aluminium upsetting simulation
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Example 1: Cylinder upsetting
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.
. . 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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Upsetting
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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
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Examples of cold upsetting
Bolt
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Coining
Upper die
Closing ring
Workpiece Tool holder
Source: Kalpakjian
2024-25 Sami Chatti BF L03 – Forging 3.35
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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
Source: Schmid
2024-25 Sami Chatti BF L03 – Forging 3.37
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Orbital forging II
Video
Prof. Marciniak
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Source: youtube
2024-25 Sami Chatti BF L03 – Forging 3.39
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Orbital forging
comparison to upsetting
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
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Content
L03 – Forging
Introduction
Open-die forging
Upsetting
Drawing out
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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
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Content
L03 – Forging
Introduction
Open-die forging
Upsetting
Drawing out
44
Source: youtube
2024-25 Sami Chatti BF L03 – Forging 3.45
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Classification of the forming processes closed-die
forming according to DIN 8583-4
Closed-die
forming
...
46
Source: youtube
2024-25 Sami Chatti BF L03 – Forging 3.47
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Classification of the forming processes closed-die
forming according to DIN 8583-4
Closed-die
forming
...
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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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Content
L03 – Forging
Introduction
Open-die forging
Upsetting
Drawing out
52
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
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Hot forging temperature
Workpiece temperature
54
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
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Forging press characteristics
Source: Lange
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Wear
Thermal fatigue
Mechanical fatigue
Plastic deformation
Source: Kannappan
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Film: Forgings – Manufacturing and Application
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