Upset forging and die design

Upset forging and its die design

1. TOPIC UPSET FORGING & DIE DESIGN BY – VIVEK CHANDRAVANSHI MECHANICAL 5 TH SEM

2. CONTENTS : INTRODUCTION PRINCIPLE CONSTRUCTION & PROCESS DIE DESIGN ADVANTAGES LIMITATIONS APPLICATION

3. INTRODUCION IT IS ALSO CALLED HOT HEADING PROCESS IN UPSET FORGING DIAMETER OF WORKPIECE IS INCREASED , BY COMPRESSING IT'S LENGTH . GENERALLY THE INTIAL WORKPIECE IS TAKEN AS WIRE OR ROD . MAXIMAM DIAMETER OF WORKPIECE , WHICH CAN BE UPSET IS LIMITED (MAX ABOUT 25 CM) HERE PROCESS CONSIST MULTIPLE CAVITIES ,THE N IT CAUSE OF MASS PROUDICTION .

4. PRINCIPLE THIS FORGING OPERATION SELECTED WHEN CERTAIN PARTS ARE REQUIRED WITH AN INCREASED DAIMETER AT CENTER OR ONLY ONE END UPSET FORGING ARE PRODUCED BY SQUEEGING PRESSURE RATHER THAN BY AN IMPACT FORCE. THIS PROCESS USUALLY DONE IN SPECIAL HIGH-SPEED MACHINE CALLED CRANK PRESS.

5. CONSTRUCTION & PROCESS: 1. PROCESS CONSIST THREE MAIN COMPONENTS , STATIONARY DIE , MOVING DIE AND HEADING TOOL . 2. BAR STOCK PLACED IN POSITION . 3 . AUTOMATIC S T O C K GAUGE MOVES A SIDE , MOVING THE STOCK IN CAVITIES OF THE DIES. 4. AFTER THE MOVING DIE AND HEADING TOOL BACK THEIR ORIGINAL POSITIONS .

6. BOLTS SCREWS CRANK PRESSS ENGINE VALVES

7. DIE DESIGN : TO ARRIVE THE SAFE AMOUNT OF UPSETTING IN A GIVEN PASS , TH E FOLL OWING THREE RULES ARE TO BE SATISFIED TO ACHIEVE DEFECT FREE UPSET FORGING : - RULE 1 : L ≤ 3 D IF NO T , THEN CAUSE BUCKLING .

8. RULE 2 . IF , L ≥ 3 D THEN CONDTION IS REQ UIRED AND COND TION IS UNSATISF IED , SO , FOR UPSETTING : DIE CAVITY WIDTH ≤ 1 . 5 D FREE LENGTH < . 5 D

9. RULE 3 . IF L > 3 D & FREE LENGTH OUTSIDE THE DIE UP TO 2 . 5 D . THEN CONDITION IS UNSATISFIED . SO FOR UPSETT ING , DIE CAVITY WIDTH ≤ 1 . 5 D BOTYOM SIZE = 1 . 2 5 D HEADIND TOOL RECESS ≥ 2 / 3 ( length of working Stock )

10. ADVANTAGES: 1.THE QUALITY OBTAINED OF PRODU C T , GREATER STREGTH . 2.HIGHER PRODUCTIVITY AND CHEAPER MAINTENACE. 3.UPSETTING PROCESS IS AUTOMATED . 4.SAVING IN MATERIAL AND NO OR LITTLE DRAFT IS NEEDED . 5.FORGING IS ACCOMPAINED WITH LITTLE OR NO FLASH.

11. LIMITATIONS: 1. NOT CONVENIENT TO FORGE HEAVIER JOBS DUE THE MATERIAL HANDELLING DIFFICULTIES . 2. MAX. DIAMETER OF STOCK IS LIMITED 25 CM . 3. UN SYMMETRIC AND HEAVY JOBS ARE DIFFICULT TO BE FORGED. 4.TOOLING COST MAY BE HIGH.

12. APPLICATION : 1 . PRODUTION OF NUTS , BOLTS , S C R E W S , R O L L E R AND BALL BEARING BALLS , V A L V E , G E A R BLANK ETC .

13. THANK YOU