1. FORGING PROCESSES COMMON FORGING OPERATIONS INCLUDE: 1. Upsetting
2. Bending
3. Drawing down
4. Punching
5. Flattening
6. Fullering
7. Swaging

2. FORGING PROCESSES COMMON FORGING OPERATIONS : Upsetting
Increases the thickness (or diameter) of a bar and reduces its length
Portion of the bar which is to be upset is heated locally
Blow of the hammer must be in line with the bar to prevent bending of the bar.

3. FORGING PROCESSES COMMON FORGING OPERATIONS: 2. Bending:
Gives a turn to a metal rod or plate
Spreads the metal in the inside of the bend narrowing at outside
Upset the bar prior to bending

4. FORGING PROCESSES COMMON FORGING OPERATIONS: 3. Drawing Out
Reduces the thickness of a bar and to increase its length
Hammering done on it on the anvil face so that force applied perpendicularly to the length axis

5. FORGING PROCESSES COMMON FORGING OPERATIONS: 5. Punching:
produces hole in metal plate using a punch
Metal job must be at near welding heat
Punch is driven part way through the job with hammer blows.
..\TEACHING\SUBJECTS\Manufacturing\FORMING\Video\Upsetting and punching.mp4

6. FORGING PROCESSES COMMON FORGING OPERATIONS: 6. Fullering:
Heated stock is placed on the fuller fixed on anvil
A fuller is put over the sock and hammering is done
Reduces the cross section of job at required point

7. FORGING PROCESSES COMMON FORGING OPERATIONS: 7. Flattening:
Reduces the thickness of job to required shape

8. FORGING PROCESSES COMMON FORGING OPERATIONS: 7. Swaging:
produces a bar with a smaller diameter (using concave dies)
usually done at the ends to make metal ready for next forming process.
provides a reduced round cross section suitable for tapping, threading, upsetting

9. FORGING PROCESSES
Different kinds of forging processes / methods:
Smith Forging: Traditional, done in open dies by manual hammer. It involves a lot of skill on the part of operator. Beneficial for small production
POWER FORGING can be classified by equipment (or, by the type of loading):
Drop Forging: Done in closed / open impression dies by drop hammers with series of blows. This involves impact load
Press Forging: Also done in open / closed impression dies by hydraulic press. This involves gradual load.
Machine Forging:

10. FORGING PROCESSES DROP FORGING Board Hammer, and Power Hammer.
Hammer is raised and then "dropped" onto the work-piece to deform it according to the shape of the die.
THERE ARE TWO TYPES OF DROP FORGING HAMMER: 
Board Hammer, and 
Power Hammer.

11. FORGING PROCESSES DROP FORGING
The energy supplied by the blow is equal to the potential energy due to the weight of the ram and the height of the fall.
POTENTIAL ENERGY= mgh
BOARD HAMMER –
• 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 blows per minute depending on size and capacity.

12. FORGING PROCESSES DROP FORGING POWER HAMMER –
• Power hammer provides greater capacity, in which the ram is accelerated on the downstroke by steam or air pressure in addition to gravity.
• Steam or air pressure is also used to raise the ram on the upstroke.
• The total energy supplied to the blow in a power drop hammer is given by

13. FORGING PROCESSES PRESS FORGING
Uses mechanical or hydraulic press to forge the metal
Uses slow and gradual squeezing action instead of a series of blows as in drop forging, therefore gives continuous forming at a slower rate.
Provide deeper penetration, impressions obtained are more clean
Better properties (more homogeneous).
Equipment is expensive

14. DROP –vs- PRESS FORGING FORGING PROCESSES
Series of Blows – Continuous Squeezing
Stock to Final Shape: Multiple – Single Pass
Less – More Dimensional Accuracy
High – Low skill Manual Labour
More – Less Vibration and Noise
Jarred – Clean & Smooth Impression

15. FORGING PROCESSES Open Die, Closed Die, and Impression Die Forging
FORGING can also be classified by the type of die as follows:
Open Die, Closed Die, and Impression Die Forging
Remember the operations can be performed:
1. Upsetting
2. Bending
3. Drawing Out
4. Punching
5. Flattening
6. Fullering
7. Swaging

16. Die may have a round, concave, or convex surface or be a tool to form holes or be a cut-off tool.

18. Fullering
Edging / Preforming
DIE - LESS FORGING
WITHOUT ANY SPECIALLY DESIGNED DIE; SHAPED SIMPLY BY HAMMERING FROM DIFFERENT ANGLE
Blocking Impression / s
COMMERCIAL APPROACH: From an ingot to the final form.
The first impression: Rough shape in accordance to the needs of later cavities;
The following impression: Cavities that more closely resembles the final product.
The final impression: Finisher impression. (It may sometimes be more economical to give a final impression in machining.)
Final Impression
Trimming

19. FLASH FORGING Points to remember: Flash is removed…
Extra (10 – 50%) Material added to ensure complete filling of die cavity
During drop forging that will form the flash
It forces metal to flow to thin ribs
Forging load can be decreased by decreasing flash thickness
Flash is removed…
by decreasing the amount of metal stock
by machining after forging
FLASH

22. FORGING MATERIALS TO BE A FORGEABLE METAL, IT SHOULD POSSESS:
the required ductility
the ability to sustain substantial high plastic deformation without fracture
SOME FORGEABLE METALS ARE AS FOLLOWS:
Al alloys 2. Mg alloys 3. Cu alloys. 4. Carbon and low alloy steels
Forgeable metals are purchased as hot-rolled bars or billets with round or rectangular cross the sections.

23. LUBRICANT in FORGING Function of lubricants:
- to minimize metal-to-metal contact by means of the specific adhesive character of the lubricant between the forge and the die.
- to reduce the coefficient of friction upon release of the forged metal part from the die.
- to extended life of the die.
- to impart high-quality surface finish