Cold And Hot Forging: Fundamentals And Applications
Among all manufacturing processes, forging technology has a special place because
it helps to produce parts of superior mechanical properties with minimum waste of
material. In forging, the starting material has a relatively simple geometry; this material
is plastically deformed in one or more operations into a product of relatively complex
configuration. Forging to net or to net shape dimensions drastically reduces metal removal
requirements, resulting in significant material and energy savings. Forging usually
requires relatively expensive tooling. Thus, the process is economically attractive
when a large number of parts must be produced and/or when the mechanical properties
required in the finished product can be obtained only by a forging process.
The ever-increasing costs of material, energy, and, especially, manpower require that
forging processes and tooling be designed and developed with minimum amount of
trial and error with shortest possible lead times. Therefore, to remain competitive, the
cost-effective application of computer-aided techniques, i.e., CAD, CAM, CAE, and,
especially, finite element analysis (FEA)-based computer simulation is an absolute necessity.
The practical use of these techniques requires a thorough knowledge of the
principal variables of the forging process and their interactions. These variables include:
a) the flow behavior of the forged material under processing conditions, b) die geometry
and materials, c) friction and lubrication, d) the mechanics of deformation, i.e., strains
and stresses, e) the characteristics of the forging equipment, f ) the geometry, tolerances,
surface finish and mechanical properties of the forging, and g) the effects of the process
on the environment.
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