FORFING DIE DESIGN FOR CLOSED DIE HOT DROP FORGING

Abstract

Forging is a controlled plastic deformation process in which the work material is compressed
between two dies using either impact or gradual pressure to form the part. Forging operation carried out
usually at an elevated temperature. It is used to change not only the shape but also the properties of the metal
because it refines the grain size and therefore improves its structure. Forging is a cost-effective way to produce
net-shape or near-net-shape components. Forged parts are used in high performance, high strength and high
reliability applications where tension, stress, load and the human safety are critical considerations. Hence, the
dies required for forging process must have a sufficient amount of strength to resist the impacts applied on it.
This is where the design factor for dies comes into play as a vital role in the forming process of a metal. The
better designed die will give best possible forged components. There are various parameters affecting the design
of a die as there no specific design for any forged product. They are made according to the component to be
forged. However, there is no specific set of methods for forging die design. Through the present study an attempt
has been made to understand & define a specific set of methodology for die design through a case study of
automobile driveline component, “companion flange”. A die was made out of design provided and was found to
be forging components satisfactorily out of it.