Simulation and optimization of material flow forging defects in automobile component and remedial measures using deform software piyush gulati 1, rajesh kanda 2. Though forging process give generally prior quality product compared other manufacturing processes. The major problem is the formation of underfills due to air pockets between the forging and the tool. Forging is a metal working process in which useful shape is obtained in solid state by hammering or pressing metal. Defects in forging during forging operation defects may occur at any stage i. There is no melting and consequent solidification involved. Hot tear defects hot tear is a defect that occurs during solidification of a casting. What are forging defects and types of forging defects forging. Defects in metal forming processes and their remedies. Rolling defects and remedies pdf these shapes are further processed through hot rolling, forging or extrusion, to. Replacement of machinery occurred during early the industrial revolution. Metal casting processes indian institute of technology guwahati.
What are forging defects and types of forging defects. Study of void closure in hot radial forging process using 3d. Defects of forged product forging a metal will also alter the metals grain. In the second and final article in a subsequent issue of forge the authors will examine the subject of materialrelated defects. The best forging companies take the necessary measures to avoid such defects. Fundamentals of forging forging or cold forming are metalforming processes. In forging processes, care should be taken else few defects are likely to a.
Understanding material forging defects 20070701 forge. A special case of internal defects that arise during cooling of forgings are flakes. Various researchers had done remarkable work in identification, diagnosis and elimination of the forging defects. International journal of mechanical engineering and.
Ref 3 the amount of machining required for completion of the part ascast dimensions may not be critical, but smooth surfaces smoother than can be obtained by sand casting are the primary objective. Additional variations include seamless ring forging, hotdie forging, and isothermal forging. Geometrical defects non geometrical defects geometrical defects. An overview of forging processes with their defects. An overview of forging processes with their defects ijsrp. Manufacturing defects of brass products and suggested. May 19, 2014 introduction forging is the working of metal into a useful shape by hammering or pressing. If the circumferential stress is tensile, longitudinal cracks occur.
Various metal forming techniques and their analysis, viz. Introduction forging is the working of metal into a useful shape by hammering or pressing. Initially, some important forging terms that are widely used in this field are discussed. Such drop forging defects can be split into two broad types. Forging is generally a hot working process through cold forging is used sometimes. Pdf forging process is used to as the primary process to achieve near.
Since ages forging defects are also occurring, leading to improper final product. Hot forging temperatures range from 93 o c 200 o f to 1650 c 3000 f for refractory metals. Forging is a manufacturing technique in which metal is plastically deformed from a simple shape like billet, bar, ingot into the desired shape in one or more stages. Discussed forging defects those repeatedly occurring along with their cause and. Surface cracks may be longitudinal or inclined at 45 o angle. Forging lap forging defects forging laps in large roll forging defects grain flow lines forging defects grains become coarse forged bar forging defects hydrogen flake in 34crnimo6 steel forging defects hydrogen flakes forging defects improper grain flow forging defects incomplete forging penetration forging defects indentation. Study of void closure in hot radial forging process using. Identification of defect locations in forged products using the finite. Grain flow is a directional orientation of metal grains and any. The forged components processed by hot radial forging have lower porosity and higher material strength. There are some defects that are lightly to come a proper care is not taken in forging process design.
Cold forging,materials,parts formed in cold forging,defects 1introduction. Upsetting cold forging of components effect of cold working on material properties the ductility of the material drops, strengths and. Although there have been some studies to examine internal forging defects reported in the technical literature, the number of articles is not large. Ghosh 1976 proposed a fracture criterion based on the shear joining of voids in the stretch forming of sheet materials, as illustrated in figure 2. A brief description of parts formed by cold forging is described with their specification. In rolling the crystals get elongated in the rolling direction. Forging manipulators have become commonplace even in the largest forging presses. Forging shop forging is a manufacturing process involving the shaping of metal using localized compressive forces. To prepare econtent and video in the area of manufacturing technology for ug and pg students and industry area project investigator. Although there are a variety of advantages of drop forging technology compared to other metal forming processes,there may still exsit some defects in hot forging process. Forging machines are now capable of making parts ranging in size of a bolt to a turbine rotor. Follow the steps in create a pdf to print a job into pdfcreator, but leave the print job in the pdfcreator window.
In the literature there is no information about modeling of such defects using fem software, therefore, attempts were made to build numerical. This forge burst in a high speed steel bar of 5in, diameter is caused by improper forging practices. A brief description of such defects and their remedial method is given below. Forging is often classified according to the temperature at which it is performed. A brief description about classification of forging process on the basis of temperature of work piece hot, cold, and warm forging and on. Cold forging,materials,parts formed in cold forging, defects 1introduction. Forging equipment also plays a vital part in ascertaining the draft angle. Analysis of casting defects in foundry by computerised.
The cure of geometrical defects such as laps, folds, underfills and geometrical discrepancies requires a change in. In this paper hot forging process of part with complex geometry such is pneumatic clamp yoke like element, is considered. Then the fishbone diagram is used to explore the possible causes of defects like unfilling, mismatch and scale pits through a brainstorming session and to. By understanding the process issues,the drop forging is better able to design its processes to minumize the occurrence of such defects. Jul 01, 2007 in this twopart series on forging defects, we have covered both geometrical defects forge, april 2007 and materialrelated defects. International journal of mechanical engineering and technology ijmet, issn 0976. A brief description about classification of forging process on the basis of temperature of work. Forging, it is a manufacturing process in which workpiece is shaped by applying compressive forces on workpiece. In forging processes, care should be taken else few defects are likely to. Crane hook, connecting rod of ic engine, spanner, gear blanks etc. Understanding geometrical forging defects 20070401. The formation of a flowby lap is shown in a gear blank forging.
Apr 04, 2011 forging and its types forging is the operation where the metal is heated and then a force is applied to manipulates the metals in such a way that the required final shape is obtained. The oldest of the metalworking arts primitive blacksmith. Manufacturing defects of brass products and suggested remedies. Less than optimum process and preform design is the principal cause of most geometrical defects. Forging is the controlled deformation of metal into a specific shape by compressive forces. In this twopart series on forging defects, we have covered both geometrical defects forge, april 2007 and materialrelated defects. Provided to fia members by colorado school of mines advanced steel processing and products research center. In the remainder of this section the articles that were found are briefly summarized. Hence, hot radial forging process is an ideal procedure to eliminate the void defects in the. Forging rolling defects forging alloy free 30day trial. The optimization of liquid forging was executed and the pilot technological process of liquid forging of automobile wheels was developed. These imperfections can be categorized differently as per their origin 27. In this first of two articles, authors van tyne and walters examine possible causes and remedies of geometrical forging defects, which are generally related to process design. The possibility of liquid forging of 17 automobile wheels out of the a356.
The shape of the pneumatic clamp is very unfavorable for forging technology and therefore defects and part inaccuracy as well short lifetime of forging tools are common. In forging processes, care should be taken else few defects are likely to appear. Opendie forging is the term applied to all forging operations, in which there is no lateral. Some examples of shapes obtained by forging process. Pdf metal forming analysis dr nirajkumar c mehta academia.
Review of analysis on forging defects for quality improvement. Identification of defect locations in forged products using the. Forging is the operation where the metal is heated and then a force is applied to manipulates the metals in such a way that the required final shape is obtained. Forging is a manufacturing process involving the shaping of metal using localized compressive forces. Forging defects virtual labdayalbagh educational institute. Though steel is poured at high temperature, this temperature is low relative to high freezing temperature range for steel. Forging defects can be categorized into two broad categories. Defects of metal forged product include, exterior and interior cracking, laps, cold shuts, improper grain flow and warping of a part. It is one of the oldest metalworking arts with its origin about some thousands of years back.
Forging is generally a hot working process through cold. Forge burst in an upset forged disc of carbon tool steel, caused by improper forging. Forging under the load of 530 tons resulted in production of the wheel with a completely formed ledge and hub and. Forging process forging defects types of forging process. Walters, forge supplement to industrial heating, vol.
Today our topic is focused on drop forging defects caused by improper heating. Opendie forging is performed on ingots, billets, or a pre. It is most preferred to combine cooling with the heat treatment, which will. Three dimensional analysis of combined extrusionforging. Pdfcreator allows you to easily merge multiple documents into one pdf file or any other output format. Closeddieforging temperatureis belowthehot range, it is warmforgingt0,5tm ok closetolerances, acceptablesurface finishnearnetshapingprocess.
649 1340 1232 684 782 74 1524 376 1314 1050 105 753 1452 1237 837 941 1178 142 820 465 270 517 1375 435 1033 826 547 349 297 1272 657 229 363 1090 1104 289 1252