This chapter discusses the factors that affect die steel selection for hot forging, including material properties such as hardenability, heat and wear resistance, toughness, and resistance to plastic deformation and mechanical fatigue. It then describes the relative merits of various materials and the basic requirements for cold forging dies. The chapter also covers die manufacturing processes, such as high-speed and hard machining, electrodischarge machining, and hobbing, and the use of surface treatments.

This chapter provides an overview of aluminum die casting and the equipment used. It discusses the advantages and limitations of the die casting process and the design and operation of hot- and cold-chamber die casting machines. It also discusses clamping systems and forces and the factors affecting die life, including die materials, metal injection cycles, and lubrication. A typical die casting cell layout is also provided.

This chapter familiarizes readers with the design, configuration, and function of tooling and dies used to extrude aluminum alloys. It discuses basic design considerations, including the geometry, location, and orientation of die openings; allowances for thermal shrinkage, stretching, and deflection; and the length and profile of bearing surfaces. It outlines the steps and processes involved in die making, describes the selection and treatment of die materials, and examines the factors that influence friction and wear. It also discusses the general procedures for on-site die correction.

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.

This chapter discusses the processes of isothermal and hot-die forging and their use in producing aerospace components. It explains how isothermal forging was developed to provide a near-net shape component geometry and well-controlled microstructures and properties with accurate control of the working temperature and strain rate. It describes the materials typically used as well as equipment and tooling, die heating procedures, part separation techniques, and postforging heat treatment.

This chapter provides a summary of ongoing efforts to improve quality and productivity in the aluminum extrusion industry. It assesses advancements in several areas including extrusion presses and auxiliary equipment, tool and die technology, billet casting, extrusion thermodynamics and tribology, and process control.

This chapter addresses the issue of die failures in hot and cold forging operations. It describes failure classifications, fatigue fracture and wear mechanisms, analytical wear models, and the various factors that limit die life. It also includes several case studies in which finite-element modeling is used to predict die failure and extend die life.

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.

This chapter discusses the factors involved in the design of impression-die forging systems. It begins by presenting a flow chart illustrating the basic steps in the forging design process and a block diagram that shows how key forging variables are related. It then describes the requirements of various forging alloys, the influence of machine operating parameters, and production challenges related to lot tolerances and shape complexity. The chapter also covers the design of finisher dies, the prediction of forging stresses and loads, and the design of preform dies for steel, aluminum, and titanium alloys.

This chapter discusses the basic differences between direct and indirect extrusion, the application of plastic theory, the significance of strain and strain rate, friction, and pressure, and factors such as alloy flow stress and extrusion ratio, which influence the quality of material exiting the die and the amount of force required.

This chapter presents a relatively simple method for estimating forging loads and flow stresses. The method uses the slab analysis technique and accounts for material properties, friction and heat transfer, press ram speed, forging geometry, and billet and die temperatures. The chapter demonstrates the use of the method and compares the results with measured values.