Abstract
Purpose of this article was to introduce a new method of forging which is called Die Forging. In this method, the required force (load) is reduced to the greatest possible degree through elimination of flash channel; however, this would also decrease the positive effect of flash channel, namely filling the gaps and pores within the mold. Cross die forging procedure provides a way for providing a better preform design which ensures that the mold is filled without allowing the material to enter the flash channel. This method has been invented based on the need to decrease the production costs and to use lower tonnage pressing devices for production of heavy parts. This method is an economical method only for parts that: A) Has at least one plane of symmetry and the two ends that are perpendicular to the symmetry plane are flat; B) Has a weight that makes it impossible to be manufactured by rolling or roll forging processes. Examples of such parts are valve's body, T-junctions, etc.
Highlights
Forging is a manufacturing process in which the part undergoes plastic deformation under compressive load and temperature
Tools and shape of the die used in open forging process do not match the final shape of the product; while, in closed die forging, shape of the die is almost the same as the final shape of the part; and to give the part its final shape, various types of preform molds are used in a step by step approach.[4]
After the cutting process, the resulting part will be used as the preform for the closed die
Summary
Forging is a manufacturing process in which the part undergoes plastic deformation under compressive load and temperature. In cross forging method, preform is designed so that it completely fills the mold, and it prevents materials from entering the flash channel In this method, all the preforms are manufactures by profile method with two open molds using hammer or pressing device. Device, dimensions of the required quadrilateral can be calculated with respect to the cross section shown in Figure (B) and anvil’s width, according to Table III: W2/2=60ÆW2=120, D2=50 ÆW’2=100, D2=50ÆX’=40,Y’=73.6. Due to the decreased pressure inside the mold in the cross die method, material flows towards the open ends of the mold rather than flowing through the flash channel, material completely fills the pores and cavities in the mold and no flash is formed. 1,2,4,5) is almost equal to the force provided by the software
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