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Forging machines
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Book Chapter
Series: ASM Technical Books
Publisher: ASM International
Published: 01 November 2013
DOI: 10.31399/asm.tb.mfub.t53740001
EISBN: 978-1-62708-308-9
Abstract
This chapter discusses the processes, procedures, and equipment used in the production of iron, steel, aluminum, and titanium alloys. It describes the design and operation of melting and refining furnaces, including blast furnaces, basic oxygen and electric arc furnaces, vacuum induction melting furnaces, and electroslag and vacuum arc remelting furnaces. It also covers casting, rolling, and annealing procedures and describes the basic steps in aluminum and titanium production.
Book Chapter
Series: ASM Technical Books
Publisher: ASM International
Published: 01 November 2013
DOI: 10.31399/asm.tb.mfub.t53740047
EISBN: 978-1-62708-308-9
Abstract
This chapter covers the practices and procedures used for shape casting metals and alloys. It begins with a review of the factors that influence solidification and contribute to the formation of casting defects. It then describes basic melting methods, including induction, cupola, crucible, and vacuum melting, and common casting techniques such as sand casting, plaster and shell casting, evaporative pattern casting, investment casting, permanent mold casting, cold and hot chamber die casting, squeeze casting, semisolid metal processing, and centrifugal casting.
Book Chapter
Series: ASM Technical Books
Publisher: ASM International
Published: 01 November 2013
DOI: 10.31399/asm.tb.mfub.t53740103
EISBN: 978-1-62708-308-9
Abstract
This chapter discusses bulk deformation processes and how they are used to reshape metals and refine solidification structures. It begins by describing the differences between hot and cold working along with their respective advantages. It then discusses various forging methods, including open-die and closed-die forging, hot upset and roll forging, high-energy-rate forging, ring rolling, rotary swaging, radial and orbital forging, isothermal and hot-die forging, precision forging, and cold forging. The chapter also includes information on cold and hot extrusion and drawing operations.
Book Chapter
Series: ASM Technical Books
Publisher: ASM International
Published: 01 November 2013
DOI: 10.31399/asm.tb.mfub.t53740163
EISBN: 978-1-62708-308-9
Abstract
This chapter describes sheet metal forming operations, including cutting, blanking, piercing, and bending as well as deep drawing, spinning, press-brake and stretch forming, fluid forming, and drop hammer and electromagnetic forming. It also discusses the selection and use of die materials and lubricants along with superplastic forming techniques.
Book Chapter
Series: ASM Technical Books
Publisher: ASM International
Published: 01 November 2013
DOI: 10.31399/asm.tb.mfub.t53740213
EISBN: 978-1-62708-308-9
Abstract
This chapter covers the practical aspects of machining, particularly for turning, milling, drilling, and grinding operations. It begins with a discussion on machinability and its impact on quality and cost. It then describes the dimensional and surface finish tolerances that can be achieved through conventional machining methods, the mechanics of chip formation, the factors that affect tool wear, the selection and use of cutting fluids, and the determination of machining parameters based on force and power requirements. It also includes information on nontraditional machining processes such as electrical discharge, abrasive jet, and hydrodynamic machining, laser and electron beam machining, ultrasonic impact grinding, and electrical discharge wire cutting.
Book Chapter
Series: ASM Technical Books
Publisher: ASM International
Published: 01 November 2013
DOI: 10.31399/asm.tb.mfub.t53740271
EISBN: 978-1-62708-308-9
Abstract
This chapter discusses the processes used in manufacturing to thermally alter the properties of metals and alloys. It begins with a review of the iron-carbon system, the factors that affect hardenability, and the use of continuous cooling transformation diagrams. It then explains how various steels respond to heat treatments, such as annealing, normalizing, spheroidizing, tempering, and direct and interrupted quenching, and surface-hardening processes, such as flame and induction hardening, carburizing, nitriding, and carbonitriding. It also addresses the issue of temper embrittlement and discusses the effect of precipitation hardening on aluminum and other alloys.
Book Chapter
Series: ASM Technical Books
Publisher: ASM International
Published: 01 November 2013
DOI: 10.31399/asm.tb.mfub.t53740325
EISBN: 978-1-62708-308-9
Abstract
This chapter covers a wide range of finishing and coating operations, including cleaning, honing, polishing and buffing, and lapping. It discusses the use of rust-preventative compounds, conversion coatings, and plating metals as well as weld overlay, thermal spray, and ceramic coatings and various pack cementation and deposition processes. It also discusses the selection and use of industrial paints and paint application methods.
Book Chapter
Series: ASM Technical Books
Publisher: ASM International
Published: 01 November 2013
DOI: 10.31399/asm.tb.mfub.t53740373
EISBN: 978-1-62708-308-9
Abstract
This chapter covers the basic steps of the powder metallurgy process, including powder manufacture, powder blending, compacting, and sintering. It identifies important powder characteristics such as particle size, size distribution, particle shape, and purity. It compares and contrasts mechanical, chemical, electrochemical, and atomizing processes used in powder production, discusses powder treatments, and describes consolidation techniques along with secondary operations used to obtain special properties or improve dimensional precision. It also discusses common defects such as ejection cracks, density variations, and microlaminations.
Series: ASM Technical Books
Publisher: ASM International
Published: 01 November 2013
DOI: 10.31399/asm.tb.mfub.9781627083089
EISBN: 978-1-62708-308-9
Series: ASM Technical Books
Publisher: ASM International
Published: 01 February 2005
DOI: 10.31399/asm.tb.chffa.9781627083003
EISBN: 978-1-62708-300-3
Series: ASM Technical Books
Publisher: ASM International
Published: 01 February 2005
DOI: 10.31399/asm.tb.chffa.t51040001
EISBN: 978-1-62708-300-3
Series: ASM Technical Books
Publisher: ASM International
Published: 01 February 2005
DOI: 10.31399/asm.tb.chffa.t51040007
EISBN: 978-1-62708-300-3
Abstract
This chapter explains that the key to forging is understanding and controlling metal flow and influential factors such as tool geometry, the mechanics of interface friction, material characteristics, and thermal conditions in the deformation zone. It also reviews common forging processes, including closed-die forging, extrusion, electrical upsetting, radial forging, hobbing, isothermal forging, open-die forging, orbital forging, and coining.
Series: ASM Technical Books
Publisher: ASM International
Published: 01 February 2005
DOI: 10.31399/asm.tb.chffa.t51040017
EISBN: 978-1-62708-300-3
Abstract
This chapter discusses the role of plastic deformation in forging and the effect of strain and strain rate on metal flow. It demonstrates the use of stress tensors and shows how metal flow can be represented qualitatively by the displacement of volume elements and quantitatively by the distribution of velocity components and strain rates. It describes the conditions associated with homogeneous deformation in a frictionless upset forging and explains how they can also be obtained using engineering and true stress-strain curves.
Series: ASM Technical Books
Publisher: ASM International
Published: 01 February 2005
DOI: 10.31399/asm.tb.chffa.t51040025
EISBN: 978-1-62708-300-3
Abstract
This chapter explains how to determine flow stress and forgeability using data from tensile tests, compression tests, ring tests, and torsion tests. It describes sample preparation, tooling and equipment, test procedures, error sources, and data plotting techniques. It also provides a significant amount of experimentally derived flow stress data, including K and n values for steel, copper, and aluminum alloys, C and m values (at various temperatures) for steel, aluminum, copper, titanium, and other alloys, and average flow stress for several alloys determined by compression testing.
Series: ASM Technical Books
Publisher: ASM International
Published: 01 February 2005
DOI: 10.31399/asm.tb.chffa.t51040051
EISBN: 978-1-62708-300-3
Abstract
This chapter covers the fundamentals of metal flow and the tools and techniques used to predict and control it. It begins by illustrating the local state of stress in a metal cylinder during upset forging and showing how stress components can be expressed in matrix form. It then explains how to determine the onset of yielding, which corresponds to the start of plastic deformation and the flow of metal within the workpiece. The chapter then goes on to present two important yield criteria, one based on shear stress (Tresca criterion), the other on distortion energy (von Mises criterion). It compares and contrasts the two methods and demonstrates their use as flow rules. It also explains how to calculate effective strain and strain rate and includes a brief discussion on the mechanical energy consumed during deformation.
Series: ASM Technical Books
Publisher: ASM International
Published: 01 February 2005
DOI: 10.31399/asm.tb.chffa.t51040059
EISBN: 978-1-62708-300-3
Abstract
This chapter discusses the factors that influence temperature in forging operations and presents equations that can be used to predict and control it. The discussion covers heat generation and transfer, the effect of metal flow, temperature measurement, testing methods, and the influence of equipment-related parameters such as press speed, contact time, and tooling geometries.
Series: ASM Technical Books
Publisher: ASM International
Published: 01 February 2005
DOI: 10.31399/asm.tb.chffa.t51040067
EISBN: 978-1-62708-300-3
Abstract
This chapter discusses the effect of friction and lubrication on forgings and forging operations. The discussion covers lubrication mechanisms, the use of friction laws, tooling and process parameters, and the lubrication requirements of specific materials and forging processes. The chapter also describes several test methods for evaluating lubricants and explains how to interpret associated test data.
Series: ASM Technical Books
Publisher: ASM International
Published: 01 February 2005
DOI: 10.31399/asm.tb.chffa.t51040083
EISBN: 978-1-62708-300-3
Abstract
This chapter discusses the role of inverse analysis in providing input data for finite element simulations of metal forming processes. It describes the basic procedures for determining flow stress and friction by inverse analysis and for comparing experimental measurements with corresponding computed data. It also includes an example in which flow stress and friction were measured in compressed aluminum rings and the results used to verify the accuracy of predicted values.
Series: ASM Technical Books
Publisher: ASM International
Published: 01 February 2005
DOI: 10.31399/asm.tb.chffa.t51040091
EISBN: 978-1-62708-300-3
Abstract
There are numerous approximate methods, both analytical and numerical, for analyzing forging processes. None are perfect because of the assumptions made to simplify the mathematical approach, but all have merit. This chapter discusses the slab, upperbound, and finite element methods, covering basic principles, implementation, and advantages and disadvantages in various applications.
Series: ASM Technical Books
Publisher: ASM International
Published: 01 February 2005
DOI: 10.31399/asm.tb.chffa.t51040107
EISBN: 978-1-62708-300-3
Abstract
Forging machines vary based on factors such as the rate at which energy is applied to the workpiece and the means by which it is controlled. Each type has distinct advantages and disadvantages, depending on lot size, workpiece complexity, dimensional tolerances, and the alloy being forged. This chapter covers the most common types of forging machines, explaining how they align with basic forging processes and corresponding force, energy, throughput, and accuracy requirements.