Forging & Press Working

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Forging Press Working

• 
  Presented by
• 
  NILESH KABRA

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SUBJECTS OF INTREST

• INTRODUCTION TO FORGING
• CLASSIFICATION OF FORGING
• OPEN DIE FORGING
• CLOSED DIE FORGING
• DROP FORGING
• HAMMER FORGING
• PRESS FORGING
• MACHINE FORGING
• FORGING TOOLS
• FORGING OPERATIONS

• INTRODUCTION TO PRESS WORK
• PRESS
• CLASSIFICATION OF PRESS
• PRESS WORKING OPERATIONS
• CUTTING OPERATIONS
• FORMING OPERATIONS

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INTRODUCTION

• Forging is process of plastically deforming metal
  or alloy to a specific shape by a compressive
  force exerted at elevated temperature by some
  external agency like hammer, press, rolls, dies
  or by an upsetting machine.
• Bolts, nuts, nails, cams, crank shafts,
  connecting rods, axles etc. are produced by
  forging.

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CLASSIFICATION OF FORGING

• On the basis of process
  
• Open die Forging
• Closed die Forging
• On the basis of equipment
• Drop Forging
• Power (Hammer press) Forging
• Hand Forging
• Machine Forging

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OPEN DIE FORGING

• This process also known as smiths die forging or
  flat die forging.
• The operation is carried out between two flat
  dies of very simple shape generally b/w the
  bottom surface of hammer top surface of anvil..
• The workpiece reduces their height/plastically
  deform by compressing it.
• The process is used for mostly large objects or
  when the number of parts produced is small to
  perform the work-piece for closed-die forging.
• Tooling is simple, inexpensive and allows the
  production of a large variety of shapes.

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CLOSED DIE FORGING

• This process is also called impression die
  forging.
• In this metal is deformed under high pressure
  between two dies (called tooling) or in a closed
  cavity that contain a profile of the desired
  part.
• Closed die forging are commonly use where mass
  production of identical more complex shapes of
  greater accuracy are required.
• The process provide precision forging with close
  dimensional tolerance.
• Normally used for smaller components.
• Closed dies are expensive.

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DROP FORGING

• It is also called as stamping. It consists of
  special type of hammer known as drop hammer or
  drop stamp.
• Perfectly made steel dies are used for forging.
• The top part of the die is raised by mechanical
  links to a certain height.
• The heated metal placed accurately in the bottom
  part of the die.
• The top part of the die is then allowed to fall
  suddenly.
• This gives a high blow and completes the
  workpiece in a single operation.

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HAMMER FORGING

• Machine which is work by blow or impact to
  perform forging process is known as hammer
  forging.

• Power hammer provides greater capacity, in which
  the ram is accelerated on the down stroke by
  steam or air pressure in addition to gravity.
• Steam or air pressure is also used to raise the
  ram on the upstroke.

• The upper die and ram are raised by friction
  rolls gripping the board.
• After releasing the board, the ram falls under
  gravity to produce the blow energy.
• The hammer can strike between 60-150 blows per
  minute depending on size and capacity.

Steam drop hammer
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PRESS FORGING

• Machine which is work on pressure to perform
  forging process is known as press forging.
• The material gets uniformly deform throughout its
  entire depth.

• The upper die and

• Hydraulic presses are load-restricted machines in
  which hydraulic pressure moves a piston in a
  cylinder.
• The full press load is available at any point
  during the full stroke of the ram.
• Due to slow speed, contact time is longer at the
  die-metal interface, which causes problems such a
  heat lost from work-piece

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• Crank press translates rotary motion into
  reciprocating linear motion of the press slide.
• The ram stroke is shorter than in a hammer or
  hydraulic press.
• The blow press is more like squeeze than like the
  impact of the hammer, therefore, dies can be less
  massive and die life is longer than with a
  hammer.

MECHANICAL PRESS
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MACHINE FORGING

• In machine forging the material is only upset to
  get the desire shape.
• The die consists of two parts, one called the
  stationary gripper die which is fixed to the
  machine frame and the other movable gripper die
  which moves along with the die slide of the up
  setter. The stock is held then between these two
  gripper dies.
• It is used for making gears, blanks, shafts,
  excels, and similar parts.

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FORGING TOOLS

• The main hand forging tools are as under.

• TONGS
• Tongs are used mainly for holding work
  
• of many section.
• FLATTER
• Flatter is used to give smoothness
• accuracy to articles which have already
• been shaped by fullers and swages.
• SWAGE
• Swage is used to reduce/finish to round,
• square/hexagonal form. It consists of
• two parts-The top part having a handle.
• The bottom part having a square shank.

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• ANVIL
• Anvil is used for supporting hot job while
  hammering is done for shaping it into various
  shapes. It is made of cast steel.

• SWAGE BLOCK
• It is used for holding hot bars during
  bending, support for punching holes in a job
  various holes.

• FULLERS
• Fullers are used for necking down/to form
  depressions.

FORGING PRESS WORKING
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FORGING TOOLS

• HAND HAMMER

• SLEDGE HAMMER

• PUNCH

• CHISELS

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FORGING OPERATIONS

• UPSETTING
• It is the operation by which the
  thickness/cross-sectional area of the work piece
  is increased at the expense of its length.
• DRAWING DOWN
• It is the operation by which the
  thickness/cross-sectional area of the work piece
  is reduced by increasing length.
• SETTING DOWN
• It is the local thinning operation performed
  by the set hammer.

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• BENDING
• It is the operation by which the bend may be
  either curve/sharp corner can be produced.
  Bending can be done using beak of anvil.
• PUNCHING
• It is the process of making holes in the work
  piece using punch hammer.
• WELDING
• It is the process of joining two surfaces of
  metal under pressure after they are heated to the
  welding temperature.
• CUTTING
• It is a form of chiseling where a long piece
  of stock is cut into several pieces of required
  length.

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INTRODUCTION TO PRESS WORKING

•  Press working is a chip-less manufacturing
  process by which various components are made from
  sheet metals. It involves the working of a sheet
  between two die. In press working, the upper die
  is called a punch. This process is also termed as
  cold stamping.
• The machine used for press working is called a
  Press. Press is a machine in which there are two
  or more slides, which move relatively to compress
  the material in the desired shape.

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PRESS

• The main features of a press are
• A frame which support a ram or a slide and a
• bed, a source of mechanism for operating the
  
• ram in line with and normal to the bed.
• The ram is equipped with suitable
• punch and a die block is attached to
• the bed.
• A stamping is produced by the downward
• stroke of the ram when the punch moves
• towards and into the die block.
•   The punch and die block assembly is
• generally termed as a die set or simple as
• the die

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CLASSIFICATION OF PRESS

• Different types of presses are classified based
  on
• Source of power
• Mechanical, Electrical, Hydraulic, Pneumatic
  etcetera
• Number of RAM
• Single, Double, Multiple.
• Method of transmitting power to RAM
• Crank-shaft, Eccentric, Cam type or rack and
  Pinion type.
• Design of frame
• Solid frame, C Frame, Movable frame, Tie rod
  etcetera.
• They are also classified based on the purpose
  and end usage.

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PRESS WORKING OPERATIONS

• The sheet metal operations done a press may be
  grouped into two categories.
• Cutting operations
• Forming operations
• In cutting operations the work piece is stressed
  by its ultimate strength. The stresses caused in
  the metal the applied forces will be shear
  stresses. The cutting operations include
• Blanking        (b) Punching         (c)
  Notching (d) Perforating       
• (e) Trimming       (f) Shaving (g)
  Slitting              (h) Lancing
• In forming operations , the stresses are below
  the ultimate strength of the metal .There is no
  cutting of the metal but only the contour of the
  work piece is changed to get the desired product.
  The forming operations include
• Bending              (b) Drawing       (c)
  Squeezing

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CUTTING OPERATIONS

• Blanking
• Blanking is an operation in which the blank
  obtained is the desired product, the rest
  
• portion is discarded.
• Punching or Piercing
• Punching is an operation in which the rest
  portion obtained is the desired product,
• the hole obtained is discarded.
• Notching
• This is cutting operation by which metal pieces
  are cut from the edge of the sheet ,
• strip or blank.

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• Perforating
• This is a process by which multiple holes are
  very small and close together are cut in
• a flat sheet metal.
• Trimming
• This operation consists of cutting unwanted
  excess of material from the periphery
• of a previously formed component.
• Shaving
• The edge of a blanked part are generally rough,
  uneven and un square. Accurate
• dimensions of the part are obtained by removing
  a thin strip of metal along the
• edges.
• Slitting
• It refers to the operation of making incomplete
  holes in a work piece.
• Lancing
• This is a cutting operation in which a hole is
  partially cut and then one side is bent
• down to form a sort of tab. Since no metal is
  actually removed and there will be no
• scrap.

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FORMING OPERATIONS

• Bending
• In this operation the material in the form of
  flat sheet or strip is uniformly
• strained around a linear axis which lies in
  the neutral plane and perpendicular its
• the length wise direction of the sheet or
  metal.
• Drawing
• This is a process of forming a flat work piece
  into a hollow shape by means of a
• punch which cause the blank into a die cavity.
• Squeezing
• Under the operation, the metal is caused to
  flow to all portions of a die cavity
• under the action of compressive forces.

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THANK YOU!!

• FOR YOUR KIND ATTENTION