Forging Design Involving Corners and Fillets

Corners and fillets are curved connecting surfaces on closed-die forgings that unite smoothly the converging or intersecting sides of forged elements, such as ribs, bosses, and webs. This article discusses the effects of several variables, including rib height, type of forging process, composition of the forging alloy, and factors associated with die filling and producibility, on vertical and horizontal corners and fillets. It reviews the design of corners and fillets to satisfy the requirements of metal flow in forging and cost considerations arising from usage and removal of metal by machining. The article presents a graphical summary of the interdependence of corner and fillet dimensions with the dimensions of adjoining ribs and webs. It concludes with information on designer's checklist for corners and fillets.