Chapter 14 Process Design in Impression Die Forging T. Altan and M. Shirgaokar, ERC/NSM, NSM Laboratory, Ohio State University FORGING is a process by which a billet of simple eros section is plastically deformed by ‘pplying compressive forcsthraigh dis or tots {0 obtain a more complex shape. In impression fie forging, two or more dos are moved towtrd teach oterto form a metal billet that seated to the appropriste forging temperature This process {scapable of producing components of high qual- Ay at moderate cos. offers a high srengih-0- ‘weight ratio, toughness, and resistance to impact tnd fatigue. Forged components find application jn the aulomobileautomotve industry and in air crafty load, and mining equipment ‘Some parts can be forged in a single set of dies, while others, duet shape complexity and ‘material flow Fitton, must be shaped in mul- tiple sets of des. Ina common mulstage forging proces, the partis fst forged in ast of busting ‘ies, then moved to one or move sts of blocking ties, and inal forged in finisher dis, Finisher fies are used to enhance geometrical deals ‘withoot significant material flow. The quality of the finished part depends greatly on the design of the previous stages Ifthe material has been ds- tebuted improperly during the blocking stage, defects may appear inthe finishing stage. In @ good-quality forging, al sections ofthe dic cav- ity must be fille, and the part must not conain flow defects, such as laps, cold shuts, o fis Before being used in production, forging des ar tested to verify proper filing ofthe di cai- ties. The most commonly used method of process verification ix die tou, in which all eal dies are manufactured and prestype pars ‘re forged to determine metal low patterns and the possible occurence of defects. This method often takes several iterations and is very cosly fn terms of time, materials, fiites, and labor Altematively, two other methods for modeling metal flow, namely, physical modeling. and process simulation using Fine-clement method (FEM)-based software, canbe used to obtain in- formation about the effects of die design and process vatables on the forging process. ‘The design of any ferging process bepns with the geometry of the finished part (Fig. 1) (Consideration is piven to th shape of the par, the ‘material to be forged, the typeof forsing equip- ‘ment tobe used the numberof pars tobe forged, ‘ho application o the pr, and the overall econcmny ofthe proces being designed. The finisher die is then designed with allowances added for Mss, di, shrinkage, fillet and comer rai, and pos ‘ionng ofthe parting line. When using multistage forging, the shapes ofthe preforms ae select, bo blocker des are designed, and the inital billet ‘omstry ix determined. In making these selec. Hons, the forging designe considers design param ‘ers such as grin flow, paring ine, ash dimen Sons, draft angle, and filet and comer rai “The terminology used to describe the fash zone in impression and closed-die forging can Funston requrensnis Partgoonet (sss ead Pacer toseos ona poe cai) Pray eassn ie oa ots) Toa capa sent prcoesnacine vrabos] ‘areblolm "Te ae dig a pr ns i Base (rcsee vrai) secon Daiaase ih ‘senator =) vee Tea i eg ems rence. ng reco corto Piste dea oa mezin dos (ONG) stinging aareers Fig. 1A sow char tring og procs dan. CNC, comput matic ol FEM iterate2./ Process Design and Workability ‘be scon in Fig. 2. The flash dimensions and bil Jet dimensions influen: ‘¢ lash allowance, that is, the material that flows into the flash zone Forging load Forging enerey © Dielife “The overall design of a forging process re- ‘uices the prediction of: © Shape complexity and volume ofthe forg- ing ‘© Number and configurations ofthe preforms or blockers ‘© The lash dimensions inthe dies and the ad- tional fash volume required in the stock for preforming and finishing operations © The forging load, energy, and center of loading for each of the forging operations Forging Process Variables ‘The interaction of the most sigifiant ari ables in forging i shown ina simplified manner in Fig. 3. Tes seen tha fora given billet material sand part geometry, the ram speed ofthe forging machine influences the stain rate and flow Stress, Ram speed, par geometry, and die tem: erate influence the temperature distribution In the forged par. Finally, low ses, fiction, and part geometry determine metal flow, forging Tod! and forging energy, and, consequently, in fluence the loading and the design of the dics ‘Thus, in summary, the following thre groups of factors influence the forging process: {© Characteristics ofthe stock or preform to be forged, low stress andthe wockabliy at var fous strain rales and deformation conditions, stock emperatue, preform shape, and soon ‘© Verables associated with the toling and li brication: tool materials, temperature, de sien of drafts and radi, configuration, ash ‘design, feeton conditions, forging stresses, tnd s0 00, © Characteristics of the available equipment: load and energy capacities, single or mut- blow availability, stifiness, ram velocity ‘under load, production rate availability of ejector, and so on Forging Materials. Table 1 lists different cheat ofa de wt nde emo sed Fig. 2 Shredders fh imal and alloys in order of ther respective ramvicety | ‘ron 2 Conese erp “pects aman ‘ene roy 1 Forotoas {Fount eeu Fig. 3. variables info forging dificuty (Ref 2). The forging, material influences the design ofthe Torgng sell 3s well 8 the details of the entire forging process. For example, Fig. 4 shows that, owing to difficulties, fn forging, nick allos allo for less shape def: inition than do aluminum alloys. Tn most practical hot Tomping operations, the temperature of the workpiece material is higher ‘than that of the des. Metal flow and ie filing are largely detormined by: ‘¢orgng material resistance to flow and ability teflo hat i is ow sess and forgeabiity ‘© Frtion snd cooling effects atthe die-mate ria interface ‘© Complexity of the forging shape For given metal, both the flow siess and forgeabiliy ae influenced by the metallurgical characteristics of the billet mafril and by the Cemperatres, strain, srain rates, and stresses that cccur in the deforming matetial. The low stress determines the resistance to deformation, thats the los, sires, and enery requirements. FForgebilty has boon used vaguely in the Hiters- ture to denote a combination of both resistance to deformation and ability t0 deform without fracture. A diagram illustrating this type of in formation is presented in Fig. 5. in general, the forgeabiliies of metals crease with inreasing temperature. However, 2s Table 1 Hot forging temperatures of different metals and alloys aca ae eet Sn, ‘Aminan aie en int) 400-500 30-98) ‘egmm oye ‘Sos aon-c) Comets (@o-s00 10-1430) CE ee eaty ale 0-115 15602100 Stic aesuede” 11001290 010-2280) Meng sel ‘0-130 0-228) ‘Desc ew meee 11001290 010-2280, ‘ett at {00-110 1830-2100 ‘Snare allo ete 1100-1250 010-2) ‘Taio ays 20-90 S070) oan prs Teso-igo sat 200) a Hst-2s0 ana) Nisam sre $0-1150 40-2100 Tien ao 1990 (920-2450) is-as0 200-20) Nettie prt: esb-tt 190-218) og aoe Ee ink) 120-130 2150-237) ig. 4 Compan of pia design tii fo ‘pce tcl oogs f l hria a toys an eke separa A dirt In ‘olin Source Refge 5 Gerenlzed dagan isang te naonce He 5 tae ‘Sed low tes om oie ing temperature increases, grain growth occurs, and in some alloy systems, forgeability decreases with increasing gran sce. The forgebiliies of tetas at various deformation rates and temper- ‘tres can be evaluated by using various tests, Such a8 frsin, tension, and compression tests In all these tess, the amount of deformation Prior to failure ofthe specimen is an indication ‘of forgeability atthe temperature and deforms tion rates used during that particular tes. Forging Equipment. Int and warm fore- ing, the behavior and the characteristics of the forging press influence: © Contact time berween the material and the dios undor load. This depends on the am velocity andthe sine of given pres. ‘The contact ime is extremely important be- cause it determines the beat transfer be- {ween the hot or warm material and the colder dies. Consequently the contact time also influences the temperatures ofthe fors- jing and that of th dios, When the coniact time is lage, the material cools down ex- cessively during deformation, the flow ‘tres increases, and the metal flow and die filing are reduced. Thus, in conventional foging operations, that is, non-isothermal, itis desirable to have short contact times. © Rate of deformation, that iste stan rte. In coztan ease, for example, in isothermal and tot die forging of tantam and nickel alloys that are highly rate dependent, te large rate ‘of deformation lads to an increase in 08 Stress and excessive desires. ‘© Production rat, With increasing stroke rate, the potential production rate increases, ro- vided the machine ean be loaded and un- loaded wih billet or preforms at these in- creased rates. © Part tolerances. Hydraulic and screw press, for example, operate with Kissing fis, that is, the dies have fla surfaces that Chapter 14: Process Design in Impression Die Forging / 3 contact each other atthe end ofeach work- Ing stroke ofthe forging press. This allows very close control of the thickness toler ances, even if the flow siess and fhition conditions change dating a production run. Ram guiding, stifness of the press fame, and drive also contribute to Tolerances that can be achieved in forging. Friction and Lubrication. The flow of metal in forging is caused by the pressure trans- mitted from the des to the deforming material therefore, te frietion conditions at the die-mate- Fal interface are extremely important and infu ‘ence the de stresses and the Forging load as well 8s the wear ofthe dies. In order to evaluate the Performances of various lubricants and to be able to predict forming pressures, it is necessary to expres the interface Friction quantitatively in terms of factor or coefficient. In forging. the ffietional shear sites, is most commonly ex pressed as: a3 where +s the frictional shear stress, is effo- tive stes, isthe friction facto, and m isthe shear fiction factor (0” m” 1). For various forming conditions, the values of im vary a follows © m= 0.05 to 0.15 in cold forging of steels, Aluminum alloys, and copper, using conven. ‘ional phosphate soap lubricants or oils (© m=0.2 to 04 in hot forging of sels, cop- pe and aluminum alloys. with graphite- based Tubvicats {© m=0.1 1003 in ot forging of dtanium and high-temperature alloys with glass Tubri- (© m=027 t 1 when no lubricant is used, for example, in hot rolling of plates siabs {and in aonlabrcated extrusion of aluminum alloys Heat Transfer and Temperatures. Hest transfer between the forged material and te dies fnfluences the lubrication conditions, de life, Properties of the forged product, and die fil. ‘fen, temperatires that exist i the material ducing forging ae the most significant variables fnluencing the success and economics of a siven forging operation In forging, the magni- fades and dstrbution of temperatures depend ‘mainly on: | ©The inital material and die temperatures (© Heat generated due to plastic deformation and fttion the die-material interface © Hea transfer between the deforming mate- rial andthe dies as well as between the dies and the environment (ar, coolant, lubricant) ‘The effect of contact time on temperatures and forging load is iusrated in Fig 6, where the lou Aisplacement curves are given for hot forging of a ‘eel part using diferent types of forging equip- ‘ment, These curves ilostae thal, duet strain rate Hoot mop 92,04 08 08 10 oy tae 189 Wpsoste 25 a al oa bs Farin ens, mete ne elaconent My Fig. 6 ond vs. daplacament canes rthe se pat ‘Grae inte ere ches wie teh volo, Vi teetoe f pert cn {hterperaure'= fi00% Or? "Fs Hy nl he ‘nesrancous igh and temperature effets, for the same forging ‘roces,lifeent forging Teas and energies are ‘required by ciferent presses. For the hammer, the {orging load is inl higher, duo wo sualn-rate effets, but the maximum load is ower than for et therhydrauticorserew presses. The reason for this {stat in the preses, the extded ash cool rap- aly whores inthe hammer, the ash emperatre remains neal the same asthe inal stock tem perature. Thus, in bot forming not only the mate ‘ial and the formed shape Dut also the type of ‘quipment used (ate of deformation and die hill. ing efiet) determine the metal flow behavior and th forming load and energy required for the proces. Surface tearing and cracking or develop ‘ment of shear bands onthe formed material often fen be explained by excessive chilling ofthe sur face layers ofthe formed part near the de-materil imerface. Production Lat Size and'Tolerances. Asis tho case in all manufacturing operations, these ‘wo factors have a significant influence on die design in forging. Ifthe production lot size is Jarge, the main reason for changing the desis dic wear. In this ease, die materials and their harnesses are selected to be especially wear re sistant, even f they are made fom somewhat ex pensive alloys. The preforming and the finishing {ies ae designed such tha eatvey Title mate tial movement is allowed in the finisher dies; ‘thus, the finisher dies, which determine the final part dimension, do not wear out easly. Tt the production fo size i small, a6 is the aao in the aroepace forging indus, die wear {snot a major problem, but die costs are very Significant Because these costs must be amor tized over a smaller mimber of pars. As a result, some of the prforming or blocker dies may be ‘omited, even if his would cause the use of more billet material. Also, in this ease the dies must bbe changed more often than in lrge scale pro- ‘duction, Therefore, quick die changing and au- tomatic die-olding mechanisms are required for economic production. Forging oleracs re very important in esign-4/ Process Design and Workabil ing the die holders and dic insets because they de pend considerably onthe manufacturing wolrances nd elastic deflections ofthe dies during forging. Prison forging of gears and blades, for example, roguires noc ony very close manafactring acura ‘des onthe dies but also close contol of di tem pate. nsdn, itis fen necessary to et- That the changes in ie dimensions under frging ‘onctons so that coretons ean be made while ‘designing and manufaeuring these des, Die di mensions vary during the forging. operation be- ‘cause of thermal expansion, mechanical loading ‘uring assembling of the dies ina holder, and me- ‘chanical loading ring the forging proces isl. Design of Finisher Dies “The most ellcal Information necessary for forging die design is the geometry of the forging to be produced. The forging geometry, in tam, Is ‘obtained from the machined part drawing by mod- ityng this port to Facilitate Forging. Staring with ‘he forging Beamer; the die designer Gist desiens the finisher dis by selecting the appropriate die ‘lock size andthe fash dimensions and estimating ‘he fori load and stresses to ascerain that the dics are not subjected to excessive loin, "The geometry ofthe finisher de is essentially ‘hat of the finish forging augmented by flash configuration. In designing finisher dis, the Iensions of the flash should be optimized. The esigner must make a compromise; on the one hand, to Gl the die cavity, iis desirable to in- ‘reas the de stresses by restricting the flash di- mensions (thinner and wider flash on the dies), ‘but, on the other hand, the designer should not allow the forging pressure to reach a high valu, Which may cause die breakage due to mechani al fatigue, To analyze stesses, the slab method fof analysis or process simulation using FEM- ‘asd computer codes is generally used. ‘By modifying the fash dimensions, the die ‘and material temperatures, the press speed and the fiion factor, the die designer is able 10 evaluate the influence of these factors on the Torgng stresses and loads Thus, conditions that appear most favorable can be selected. In addi tion, the calculated forging-sres. distribution can be used for estimating the local de stresses Inthe dies by means of elastic FEM analysis. ‘Afr these forging stresses and loads are esti ‘ated, itis possible to determine the center of leading forthe forging in order fo locate the die cavities inthe press, sch that off-center loading is reduced, Flash Design in Closed-Die Forging. As ‘mentioned earlier, the Mash dimensions and the billet dimensions influence the Mash allowance, forging load, forging energy, and the die life ‘The selection of these variable influences the quality of the Forged part and the magnitude of fash allowance, forging load, andthe di lif. ‘The influence of flash thickness and Mash land wid on the forging pressure is reasonably well lnderstood from a qualitative point of view. The forging pressure increases wth: Decreasing fash thickness Tnereasing flash land width because of the ‘combinations of increasing restiction, creasing ftitional forces, and decreasing metal temperatures atthe Hash gap lash Dimensions. The variations in the lsh ‘dimensions influence the forging load, forging en- ‘erg, and the Mash allowance used t determine tho Intl matral (billet) volume. The dimen- sions ofthe fash can be varied in tee ways © Changing the Mash width with constant thickness ‘© Changing the flash thickness with constant with (© Changing the ash width and thickness with ‘constant with-thickness ratio Chowsing the Flash Whdth and Thickness. Several facors influence tbe choice of a good fash thickness. The choice ofthe fash thickness is influenced by the pat weight as wel a the shape complexity (Fig 7). Based on the complex~ ity the majority of forging pars are classified into: ‘© Compact shape, spherical and cubical (cass i) © ise shape (class 2) 1 Oblong shape (lass 3) ‘The first group of compact shapes has the three major dimension, namely, the length () breadth or width (), and the height (), approx: imately equal, The number oF parts that fl nto this group is rather smal “The second group consists of disk shapes for Which two of the thee dimensions (length and casa | epee seal coaesa0n edhe cxkza | oll | clita | Ca | wan [S| | ot | ae | EB | ae Fig. 7 clesticaion oon tape lengh:w wi eght, Sores: Re 3Width) are approximately equal and are larger than the height. Al the round forgings belong to ‘his group, Which includes approximately 30% ‘of all he commonly used forgings. ‘The third group of forgings consists of long shapes, which have one dimension signfieandly large than the other two (U> w =). ‘These three basic groups are further subdi- vided into subgroups. depending onthe presence ‘and iype of elements subsidiary to the basic shape, This classification is useful Tor practical [usposes, suchas estimating costs and prediet- Ing preforming step This method, however, is ‘ot entirely quantitative and requires some sub- jective evaluation based on past experience Depending on the shape complexity of the part that the user desires to produce, a range of ‘raps can be selected foreach group. Figure 8 shows a graph for selecting the flash thickness based on the weight, , of the forging {or a particular group of forgings. This graph shouts the relationship between the flash width thickness (wi) ratio and the forging weight Thos, knowing the weight of the part 10 be orga, itis possible to find the coresponding ‘ash thickness and wt ratio, Thus, the ser ean ‘obtain the flash dimensions based onthe weight ofthe forging “There is no unique choice ofthe flash dimen sions for a forging operation, The choice is ar able within a range of values where the flash a- Jowance and the forging ood are not t00 high. ‘There has o be a compromise hetween these vo. Empirical Formulae, ‘There are diferent sets of formulae, based on billet dimensions, to determine the flash dimensions. These dimen- ‘ons are used to obtain lit lash allowance and to minimize the forging enerey For round forgings, Eq 2 and 3 predict ash dimensions that ae a good compromise between fash allowance and forging load (Ret 4): stor Diaz] Tz] Where w is the fash width, (mm). the Hash Thickness, (mim). His the height of the ribs or shaft, Dis the outside dismeter of the forging, tnd isthe radial distance of the center of a ib from the axis of symmetry of the forging. 42) 49 Preform (Blocker) Design in Impression-Die Forging Ope of te mom ingonam aspects of los dis erging the eng of petro blockers touclee azqute mel dtibaon. The de ‘eominadon of te preform conigunion i an ‘spect it ak anda a by Hel ling sh achieved only by sear of exten in peforning, round of roundcomered sane sok wil const cos svn de Fred in cha muner at Gecet yolome 0m 60] 3.0] 008 20] ash henooe 22 Fie 8 aie Sowce'ma 5 10 10 a 2 mo 2 8 Foring weit. ‘Varin in ash chs (and width airs (0 alo for avon and alloy sel ings free (Chapter 14: Process Design in Impression Die Forging /5 Aisuibution is achieved prior to impression die {orging. In blocking, the preform is forged in 2 blocker cavity prior to fnish forging. Designing 8 comect preform allows the contol of the vol- ‘ume distribution of the part during forging as ‘well as control over the material flow. The ob- Jectives of preform design are: (© Ensure defect free metal flow and adequate ie filing ‘© Minimize the amount of material lost as ‘ach (© Minimize die wear inthe finsh-forpingexy- ity by reducing the metal movement inthe ‘operation (© Achieve desired grain flow and control me- chanical properties ‘Basie Rules of Preform Design. In forging steel parts, a eomect preform canbe designed by ‘sing the following thse general design roles (Qhese rules do not apply to forging nonferrous materials) © The area of cross section of the preform equals the ara of cross section of the fin- ished. product plus the flash allowance (metal flowing into flash, Thus, the initial Hock distribution is obtained by determin- ing the areas of cross sections along the main ais ofthe forging. © Al the concave radi, including the filet ‘adi, on the preform must be greater than the comesponding radi on the finished part (© In the forging direction, the thickness ofthe reform should be greater than tha ofthe fin ‘shed part so thatthe meal lo is mostly by ‘peti ruber than exirason. During the ‘ishing stage, the material is hen squeezed laterally toward the die cavity without si ‘ional sear atthe die-material imerface. Soch ‘conctons mime friction and forging load and reduce wear long the die surfaces In attempting to develop quantitative or ob- Jective engineering guidelines for preform de- ‘ign, thorough understanding of metal flow is essential. Metal flow during forging occurs in ‘wo basic modes (© Paral to the motion of the dis, that is, ex- (© Perpendicular to the motion ofthe dis, that is, upseting Conventionally, blocker dies were designed sing some guidelines, which are summarized as follows. Prior to the advent of computer-aided design methods, blocker dies and preforms were {designed by wyouts. The guidelines used depend fn the material and the forging machines used (© The blocker is slightly narower than the finisher inthe top view by approximately (05 to 1.0 mm (0.02 to 0.04 in) and hes larger illet and corner ral. This helps en- hanced metal dstribation. (©The acas of the various blocker cross seo- tions are augmented from those of the fn- isher by the fash allowance.6 / Process Design and Workability (© To forge high ibs in the finisher, those in the blocker ar, at times, shorter. Addition- ally, the web thickness in the blocker is larger shan tat in the finisher. (@ Torenhance the metal flow toward the ibs, an opening taper may be usefl from the ‘center ofthe web toward the bs. '¢ In the case of set forgings, whenever pos- sible, the ribs inthe blocker sections should bbe narrower but slighly higher dan those in the Tnsher sections fo reduce the die wea. ‘The common practice in preform design i to consider planes of metal flow, that s, selected cross sections of the forging (Fig. 9). Understanding. the principles of the material flow during the forging operation can help attain better understanding of the design rules. Any ‘complex shape can be divided into axisymmetric ‘or plane-struin flow regions, depending on the geometry in order to simplify the analysis ‘The example ste! forging preseated in Fig. 10 ‘Mustrates the various preforming operations nec- ‘eseary to forge the part shown, The round bar from rolled stock is rolled in a speci machine called a reducer roller for volume distribution, ‘bent in @ die to provide the appropriate shape, ‘locked ina blocker die cavity, and finish forged. ‘In determining te forging steps fr any part is ist necessary to obtain the volume ofthe org- ing based onthe areas of sucessve cross See- ‘ions throughout the forging. The volume distr bution can be obtained in the following manner Lay outa dimensioned drawing of the finish configuration, compete with lash 2, Construct « baseline for arca determination parallel to the centerine ofthe part. 3, Determine the maximum and minimum cross-sectional areas perpendicular 10 the centerline of the part 4, Plot these area values at proportions di tances from the baseline. Connect these points witha smooth curve Above this curve, add the approximate area ‘of the ash at each cross section giving con- Seration to those sections where the flash should be widest. The flash is generally of ‘constant thickness but is widest atthe nar- rover sections and smallest st the wider seo 7. Convert the misimom and maximum area ‘aloes to rounds o rectangular shapes having the same cross-sectional area. Figure 11 shows two examples of obtaining a volume distbution through the previously men- ‘oned procedure. “The applications ofthe design rules for pre- forming ae illustrated by examples shown in Fig. 12. Figute 13 shows some suggested blocker and finish cross sections for varius steel forgings ‘The preform is the shape of the billet before the finish operation. In cetin cases, depending on the ratio of the height ofthe preform to its ‘width, there might be more than oe preform op- ‘ration involve. o Fig, 9 Planes ard decon of tallow rng ig of un pl shapes Ut and 2 complex shape gt a) Planes ow} Fes shape Drectons of fom = Fig. 10. Peoming Hocking nd inhdorgng oer ‘Mone orn example el ong ee: at reform design guidelines difer from mate- rial to material, They are basically categorized imo the following thre categories © Carbon and low-alloy stel parts ‘© Aluminuon alley web-rib-ype parts © Titanium alloy web-ib-ype parts Guidelines for Carbon and Low-Alloy Steels. In hammer forping of carbon or low- alloy steels, the preform usually does not have fash The blen-in radius of the preform (R) at the paring line i influenced by the adjeent cavity depth (C) CTable 2). Inthe preform, the ‘let radius (py) between the web to a 1b is larger than that fa the ish forging (Ry), expe- cially when the height of the rib over the web is Jaeger than the ib wid, that is, Dy > wp (Fe 19) Guidelines for Aluminum Parts. For sib websiype aluminum alloy pars, the recom- ‘mended preform dimensions fall nt the ranges sven in Table 3. The preform is usually de- ‘ened to have the same dra angles a the finish art, However when very deep cavities ae pres- ‘enti the finisher die, larger draft angles are peo- Yided in the preform. A greater web thickness in the preform is selected when the web reais el ‘atively small and when the height ofthe adjoin Ing ribs is very large. A comparison of the pre farm andthe ished pa asad ia Fi 1 Guldelines for Titanium Alloys. The guide tines for designing titanium alloy preforms (Table 4) ae similar to those fr aluminum alloys In designing forging dies, he forging sresses and Toad must be estimated in order to predict Whether the dies may break under load or not and to select the forging machine with adequate Toad and energy capacity, In most multistage forging operations, the finish-forging operation requires the highest load because inthe finisher ie, the thickness ofthe forging and all he filet land comer radiate reduced to obtain the final part geometry. Prediction ofthe forging load and pressre in loved or ipresson-de forging is dificult due to the nonsicady state ofthe press, that is, vari ables afleting the process, such as temperature, ‘tresses, and on. In addition, forgings comprise fan enormously large number of geometrical shapes and materials that require diferent, even ‘hough sia, techniguos of engineoring analy. sis. The following methods are generally used for etenmination ofthe forging sreses and loud ‘© By empirical frmulze, based on past expe-° sf =i sean fe DI oie sa @ Fig, 11 Perm designs fr two example pars In '& TY Co examper: (a) Fong 0) Cos sectoral ae mah) an) a pee Y a {volume and cot acon ofthe mah ot ep tay a volume nd rs section of he ash, reno Suices Res © By performing approximate calculations through one of the Well-known methods of plasticity, such as slab, upper bound, slip Tine, or FEM, Load-Stroke Curves, A typical load-ver- sus-stoke curve for a closed forging oper tion indicates that loads are relatively lo until the more dificult dots are partly filled an the ‘metal reaches the lah opening (Fig. 16, 17) This stage coresponds to point Py in Fig. 17. For successful forging, two conditions must be fulfilled when this point is reached (Ret 8) © A sufficient volume of metal must be trapped within the confines ofthe die ofl the remaining cavities. Chapter 14: Process Design in Impression Die Forging / 7 i Le Ep mien Ce ea eo va] =a mrp Fis nea Fig, 12 Proms odie Hshape ois bet by ead. Source Re Fig. 13 [oie pom: fer Source Re ‘Table 2 Preform dimensions for carbon or low-alloy tees = Blatant) teri) Dept ety Wie ee pene ta 0. ‘sen =m 2) Men a ten a a Spat ga cls Serna (© The extrusion of metal through the narow- ing gap ofthe Nash opening must be more Beurtellen des Werkstickes hinsichtlich Gravurausfbllung, Gratentstehung und Oberfis- chengate > Vergleich mit den Ergebnissen der Simulation von FORGE 3D. > Ermittein der Maximaikraft und Vergleich mit der theoretisch berechneten Maximalkraft > Beurteilung des Kraft-Weg-Verlaufes > Diskussion der Ergebnisse 6 Literatur {LAN77] Lange, K.; Meyer-Nolkemper, H.: Gesenkschmieden Berlin, u. a: Springer-Verlag 1977 [LANSB] Lange, K-: Gesenkschmieden von Stahl Berlin, u. a: Springer-Verlag 1958 [TSC77] __Tschatsch, H.: Taschenbuch Umformtechnik. Manchen: Hanser -Veriag 1977 {LAN88] Lange, K: Umformtechnik. Handbuch fir Industrie und Wissenschaft, Band 2: ‘Massivumformung. Berlin, u. a: Springer-Veriag 1988 [HER74] Herold, G.; Herold, K.; Schwager A: Massivumformung. Berlin: Verlag Technik 1974 [BIL73] Billigmann, J.; Feldmann H.-D.: Stauchen und Pressen. Monchen: Hanser-Veriag 1973 [BEI97]_ —_—_—Beitz, W,; Grote, K-H.: DUBBEL. Taschenbuch des Maschinenbaues. 19. Auflage. Berlin, u. a: Springer-Verlag 1997 6 —Arbeitsschutz ‘Wabhrend des Praktikums sind das Hineinlehnen bzw. Hineinfassen in den Arbeitsraum der Erwarmungseinrichtung und der Werkzeugmaschine untersagt. Wegen des Gefahr des Weg- spritzens von erwarmten Werksticktellen ist gebthrender Abstand zu halten. Vorhandene ‘Schutz- und Sicherheitseinrichtungen durfen nicht verandert werden, 7 Verantwortlichkeit Dipl.-Ing. Hubert Rosler Zimmer 2E 021 Tel. 831-326 83 ser@mb tu-chemnitz de 326 ‘Tel. 31-3 25 75 wemer.volgt@mb tu-chemnitz.de Dr.-Ing. Werner Voigt,_ Application au calcul de bavure ® Dimensionner le cordon de bavure ® Calculer la masse tombante ® Définir le nombre de coupsformules © K=A/B= épai moyenne intégrale largeur moyenne intégrale ® Epais moy (cm)= Volume piéce+Volume cordon Surface piéce+Surface cordon | | ® Largeur moy (cm)=surface piéce + surface cordon Longueur de la piécelogement oe bavure brevoiearbt do meta ca eciaar eu STS ees Saran Oamatemmnma | y Caeut © ton 9) complente $ eel ey rae aay eo ae en Pidces pase ao-| oe. ogee Tres es - 0 = | 9» i 1 |fi0)- Bele pele |, s+ | 2 a Des | Bt pated lt no. | : (\\_20 + | 15 Ly er i) etal eee ees xo. | 7 2 cu aa Pisces Ee i Frokh B20 [en a oyee cs f ‘ = Sees 4 Coa a crema [asses airs calculé ne doit jamais tre intéieur 81.2 me. {enc pewri wn sin, acopt 1.2m tcl 4 on corer ta retation vmposte parle caractere a On observers que la bavure (proptement dite igure) expulhe du cordon a interven pes (sus Verte cer pas empl he logement de bsvure)C'est le surplus nécessaire au bon remplissage de l'empreinte. Le réle de la bavure est également de freiner écoulement de métal et donc d’augmenter la pression a l’intérieure de l’empreinte pour favoriser son remplissage. La dimension du cordon est trés importante, la largeur dépend de la dimension mini et I’épaisseur de la complexité Sa ¢ | Logement du supplément de matiére La bavure occasionne généralement 10a20% de matiére en plusdétermination technologique de la vitesse d‘impact ou de la hauteur de chute et de la masse spécifique unitaire a a wumolicité Croquis sehématique idces massives | Pieces semw-dparises | Pidces semi plates r M rn complete by rete esse ees sep Prbeevlates | idee es pater | Heute Kz 020 OMSK <020 0S K< OK 0078 < 010 K<007 bai me | eee OY w | 6 Karem B oem 10 icm 12 kare VA gfe | ad 528 (NE JAMAIS OMETTRE. De CONSULTER Le TABLEAU CORRECTIF DE CELULCH Pour ie pacer dont ess suppowe qua a pice eit Vande oy carte ou, dn vigues, pe ‘oxedie ps 3 oii anger moyenne 8 (at Srislongieur exchde 3 foiscatetorgeut srs ‘angular, Oane carne cr aut Tele wulement cles don Ta longueut“A 1 Recteslnoies faliymsaneriacar: men maces Perens Sete ie ese | naeceaut ee | ska Rs | RaeTRG a IST bavure |bavure |bavure [bavure [bavure [bavure n peta et tappe 2 trapper 85 4 1255 25 ar trappe ole 2rapes la 3 froopes 126 4 2506 2 2 Stropoes pe steappes ofS mi a0 is Se kfeneeee leo tiearee B01 4 1k 1 Kx trappes ple Stappes Btrappes 7 14 2k 095 8 | 6 be Ttappe of 2 | 9 24 ang 020 6 |e 7hape of @ | 9 | 10 44 aks os 7 \ife) Vegawelieta |e jee 8 4 16K 080 a fo fa faz fas | os 16 4 32k9 078 wo [i | is |e | ve 4 6tks 070 a | 16 18 | 20 Ce Tableau 3 est le correctif du Tableau 2 dont il est inséparable. Le multiplicateur révélé par ce tableau modifie la Masse spScifique unitaire (Msp) recusillie grace au ta- bbleau 2 mais il n‘altére pas la vitesse d'impact (ou encore hauteur de chute libre), dont a valeur dépend d'un tout autre critére, La masse ains! multiplige par un coe'ficient correcteur ne cesse pas de dépendre du caractére de “massivi- ‘té:minceur" mais dépend en outre du poids de objet a produire. Ce sont des considérations 4 la fois économiques (et technologiques} qui imposent cette correction et qui décide du nombre de frappes. ‘Le nombre des frappes croit avec le % de bavure. |i est révélé par ce tableau.a Forgeage Page : 1 Forgeage d'une bielle Une bielle de moteur & quatre temps destiné a Ia motoculture doit étre produite & environ 5 000 unités par an, La production est planifiée sur 5 ans. Fonetionnellement, cette bielle peut étre indifféremment produite a partir d'un brut gorgé ou usinge dans la masse. etude ci-dessous permet de s'interroger sur la méthode de réalisation la plus pertinente. Données : = les fichiers suivants sont disponibles sur "intranet : = bielle finie (forgée) = bielle brute avec bavure = bielle brute sans bavure ~~ outilage pour forgeage Travail demandé 1- Matériau Le matériau de ta bielle est de l'acier 16 Ni Cr 6. = Préciser la signification de la designation de ce matériau 2- Recherche débit pour usinage La bielle étant totalement usinée a partir d'un brut de section rectangulaire : = proposer un processus permettant de réaliser la bielle, - _déterminer les dimensions de la piéce brute. 3- Conception de la bielle forgée ‘On vous propose (document réponse 1) en trait double mixte fin les surfaces fonctionnetles (dimensions, épaisseur minimales) de la bielle. Esquisser le brut de Ia bielle en respectant les contraintes liées au procédé d’obtention. Indiquer clairement le plan de jon, les dépoulles,rayons de raccordement et surépalsseurs dusinage. 4- Processus de réalisation de la piéce forgée Proposer un processus complet de réalisation de la pice foraée §- Caicul du lopin La pidce avec bavure est fournie au format CATIA V5. A fide de ce fichier, proposer le volume du lopin a utiliser. Lentreprise utilise, pour Facier 16 Ni Cr 6, des bruts laminés de diamétre : 20 - 25 — 32 ~ 40. On considére que pour un remplissage correct de fempreinte, Ia longueur du lopin doit étre voisine de Déterminer les dimensions du lopin @ utiliser. STS IPM — Etude des produits et des outilages t-teForgeage Page : 2 6- Contraintes économiques Données : - Forgeage — Cott frappe de la pidce + retrait bavure : 1 €/ piece = cott outilage : 15 000 € colt débit lopin : 0,5 € /piéce - Usinage = codit horaire usinage CN :65€/h = débit moyen de copeaux : 500 mm/s (valeur indicative utiisée dans l'entreprise pour effectuer les devis pour les usinages classiques sur MOCN) = codt sciage : 1 €/ piéce = coit matériau : 3,3 €/ kg = masse volumique matériau : 7860 kg/m? Compiéter le tableau « Document réponse 2 » puis le graphique ci-dessous : o 40000 20000 Quel procédé semble-til le plus économique par rapport a la série prévue ? ‘STS (PM ~ Etude des produits et des outilages cnt| Page Informations techniques : ~ Matiére forgée : 16 NiCr 6 = Dépouilles : 3° Document ressource 4 ‘Sens de la frappe Plan de joint = Les deux alésages ne sont pas réalisés lors de la phase de forgeage mais sont Abauchés de chaque coté de ia fagon suivante S) VL ae Sens de la frappe Dimensions Valeur des Gamme oimensions | ‘naamace Tolsronces | Rugosie Piaumice | ago | soratset | aéoacsew | SSrmcoe| obtono Ra (enmm) aon ts (en mm) (enmm) (enmm) (en um) Forgeage| 200ae00 | 10ar000 | 1a20 | sazso | ovaa | azarae = Lentreprise fait sous-traiter fopération de forgeage. = Les usinages se déroulent sur un centre d'usinage 3 axes 4 commande numérique. = Les surfaces nécessitant un usinage doivent avoir une réserve d'usinage prévu lors de la phase de forgeage. Cette réserve est de 3 mm. STS IPM Etude des produits ot des outilages nee p-tomeost| asuodgu juewns0qPage : 4| Document réponse 2 Tableau a compléter Bisliousingo | _——_—_~Blolle Forgée | (Coat matidre Volume brut Volume brut: Masse du brut Masse du brut | coat matigre ‘coat matiére Contasbit: | Coat sciage: Coat debit: Coat forgeage (Coat forgeage Coat usinage [Volume avant usinage |Volume avant usinage : (Catia) ‘Volume aprés usinage : (Catia) Volume copeaux : Temps usinage [Coat usinage : ‘Volume aprés usinage : (Catia) Volume copeaux : Temps usinage : ‘Coat usinage ‘Coat total STS IPM ~ Etude des produits of des outillages