PRESENTATION ON

PREPARING SHAPES BY FORGING

MADE BY :

DCRUST, MURTHAL

FORGING SHOP

Forging is a manufacturing process involving the shaping of metal using localized compressive forces. Forging is often classified according to the temperature at which it is performed: "cold", "warm", or "hot" forging. Forged parts can range in weight from less than a kilogram to 580 metric tons.Forged parts usually require further processing to achieve a finished part.

TYPES OF FORGINGHOT FORGING: It is the controlled plastic deformation of metals at elevated temperature by using the external pressure.The pressure may be applied by hand hammers or power hammers .So in this ,pressure apllied is not continuous but intermittent.Following are some of the examples of hot forging

1.HAMMER OR SMITH FORGING2.DROP OR DIE FORGING 3.PRESS FORGING 4.UPSET FORGING5.ROLL FORGING6. SWAGGING

HOT FORGING

PRESS FORGING

Press forging uses the impression dies but plastic deformation of metal is done by a slow squeezing action.The presses used for press forging are:Mechanical press (crank,electric,knuckle) and hydraulic press.

PRESS FORGING

SwagingIn this process of hot forging rods or tubes are reduced in size by the repeated blows of opposed .The repeated blows cause the metal to flow inward and take the shape of die

Swaging

COLD FORGING

Cold Forging is a cold working process where the material is squeezed into a die and the finished parts assume the shape of the die. This process is also known as Cold Heading.

Applications of forging

• The portion of work in which forging is done is termed as forge and the work is mainly performed by hammers,machines,and presses.

• Forging processes are among the most important manufacturing techniques as it is used in small tools , automobile sector, as well as home and other accessories.

FORGING TOOLS AND EQUIPMENTS

1) TONGS : USED FOR HOLDING WORK EHILE DOING A FORGING WORK.

2) HAMMER : USED FOR HAND FORGING.

3) ANVIL : ACTS AS A SUPPORT FOR FORGING WORK.

4) SWAGE BLOCK : USED FOR SIZING, SQARING AND BENDING.

5) FURNACE : USED FOR IN HOT FORGING FOR HEATING THE METAL PIECE TO RED HOT.

Advantages and disadvantages of forging

ADVANTAGE DISADVANTAGES

No weight loss. 1.High tool cost

Smooth surface 2.High tool maintenance

High speed of production 3.Limitation in size and shape

TYPICAL FORGING DEFECTS

•Pitted surface, due to oxide scales occurring at high temperature stick on the dies.

•Buckling, in upsetting forging. Subject to high compressive stress.

•Microcracking, due to residual stress.

•Flash line crack, after trimming-occurs more often in thin workpieces. Therefore should increase the thickness of the flash.•Cold shut or fold, due to flash or fin from prior forging steps is forced into the workpiece.

JOB OF FORGING SHOP

SCREW DRIVER BY HOT FORGING

TO PREPARE “S” HOOK BY FORGING

1.Cut the required length of metal piece with hacksaw

1.Then mark the required dimensions on it

3.Heat the M.S. rod in coke fired furnace till red hot temperature .Re0move the job from furnace and make the required shape

And size of the job piece on one side.

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