Forging of MetalsIntroductionLading-gear components for the C5A and C5B transport aircraft, made by forging.Outline of Forging and Related OperationsGrain StructureOpen-Die ForgingSlide 7Slide 8Impression-Die & Closed-Die ForgingSlide 10Slide 11Precision ForgingCoiningTHE ENDForging of Metals Chapter 14Introduction A metal is shaped by compressive forcesOldest metal working process – 4000BCCan be performed with a hammer and anvilTypical forged products:BoltsRivetsConnecting rodsGearsLading-gear components for the C5A and C5B transport aircraft, made by forging.Steps involved in forging a bevel gear with a shaft.Outline of Forging and Related OperationsGrain Structure Parts have good strengthHigh toughnessForgings require additional heat treatingFig : A part made by three different procedures, showing grain flow (a) casting (b) machining (c) forgingOpen-Die ForgingIs the simplest forging processSizes can very from very small parts to very large partsOpen-Die ForgingUpsetting or flat-die forgingUpsetting or flat-die forging – a solid workpiece is placed between flat dies and is compressedBarreling caused by frictional forces at the die-workpiece interfacesCan be minimized if a lubricant is usedThermal effects caused by barreling can be minimized by using heated diesOpen-Die ForgingForging forceImpression-Die & Closed-Die ForgingThe workpiece acquires the shape of the die cavities while being forged between the two shaped diesImpression-Die & Closed-Die ForgingThe blank to be forged is prepared by: Cutting from a bar stockPreformed blankCastingPreformed blank from prior forgingImpression-Die & Closed-Die ForgingFullering & edging are used to distribute the materialFullering – material is distributed away from an areaEdging – material is gathered into an areaBlocking – rough shaping of the partImpression dies – give the part its final shapePrecision ForgingPrecision ForgingUsed for economic reasonsThe part formed is close to the final dimensionsLess machining is neededHigher capacity equipment is neededAluminum and Magnesium alloys work well in the processCoiningCoining Closed-die forging processUsed for minting coins, medallions, & jewelryLubricants can not be used in coiningCan be used to improve surface finishTHE