Forging process produces parts of superior mechanical properties with minimum waste of material. The invention discloses a finite element modeling method for predicting forging force in the rotary swaging process and belongs to the technical field of plastic forming. Energycontrolled rotary swaging process for tube workpiece. Pdf a new analysis model is presented to simulate both the cold swaging process and hot radial forging process. We take a tube or a solid rod and reduce the outside diameter down to a specific diameter. According to the forging temperature, forging can be classified into hot forging, cold forging and warm forging. Pdf rotary swaging forming process of tube workpieces. Sand casting is the more economical process for fewer than about 20,000 pieces. Dec 11, 2016 forging fullering,flattening,swaging learn and grow. Types of forging processes forging industry association. Rotary swaging is an incremental cold forming process and allows for the cost.
The segments of the forming tool 2, 3 or 4 split molds apply pressure radially on a turning part. The english origin of swaging dates back to the 19th century. For the recess method, the main deformation area is the forging zone. Metal forming processes indian institute of technology guwahati. Rotary swaging is used in the manufacture of various parts for the automotive, aerospace and defense industries, for example, in the production of pipes, hollow steering columns, drive and guide shafts as well as various fasteners. Even though roll forging uses rolls in order to accomplish the deformation of the material, it is classified as a metal forging process and not a rolling process. The present module describes the salient aspects of forging process.
May 05, 2017 today we will learn about swaging process. The book package includes four print books and three ebooks on cdrom, including the bullet swage manual, technical bulletins and ebooks power swaging, corbin handbook of swaging no. Forging is a metal forming process in which the metal is heated and a force is applied in such a way that a required shape can be obtain. Rolling, forging, extrusion and drawing are bulk forming processes. Forging process for hollow axle shafts uses differential. It is usually referred as hot pressing, and is carried out either using hydraulic presses or mechanical. Bulk metal forming, dry metal forming, radial forging. Swaging and sawing services we offer costeffective manufacturing solutions for automotive, air conditioning, and other applications through chipless swaging and tube end forming processes.
Sections on bending, end finishing, coating, and tube design provide previously hardtofind information that will help to minimize the cost of your. Dry rotary swaging approaches for lubricant free process design. The forging force is calculated by an empirical formula in the conventional rotary swaging industry, the calculation accuracy is low, and the change rule of the forging force. In this ebook, we will explain you all aspects of metal forging. In this process, the starting material has a relatively simple geometry.
Finiteelement model to investigate the metal flow of rotary swaging process of tubes, metal forming simulation software transvalor forge 2011 3d was used to simulate the process. Depending on the forming degree, the process will be executed in cold or hot condition. Due to the growing scrutiny into the fuel consumption and emissions of class7 and 8 heavyduty vehicles hdvs, reducing vehicle weight is becoming. To deal with the effect of manipulator or tool for material handling, the presented. The forming technique is based on the differential heating of a tubular billet. Finite element analysis model of rotary forging for. An overview of forging processes with their defects. Pdf finite element analysis of tube swaging and radial. Crane hook, connecting rod of ic engine, spanner, gear blanks etc. Apr 24, 2017 forging is a metal forming process in which the metal is heated and a force is applied in such a way that a required shape can be obtain.
Forging process for hollow axle shafts uses differential heating. Therefore, local uniform necking occurs on the tube or bar material owing to the multidirectional forging and highfrequency loading method. Our swaging machines are best suited for making high quality connector pins and attaching pipe fittings as well as small mechanical components. Opendie forging is the term applied to all forging operations, in which there is no lateral constraint except for friction and consequently no threedimensional confinement. The swaging process in reference to cold flow of metals into bullets is the. It is can sometimes be done as a hot working process and is considered forging. The recess swaging process is often used to reduce diameter at a certain position of the workpiece or form a concave profile. Rotary swaging is a highperformance forging process for hollow and solid parts with an elongated axis. Lets make a swage press ok folks, time to make one of these lead mashers i know many of us discussed the. The ultimate guide of metal forging free pdf download metal forging plays an important role in the manufacturing industry. Thanks to our extrusion process, no air bubbles are trapped inside the metal. Chapter 16 10 bulk deformation processes rolling forging extrusion wire, rod and tube drawing cold forming, cold forging and impact extrusion piercing other squeezing processes.
The heavyduty rearaxle shaft and piniongear shaft are used to. Some of the smaller parts are actually forged cold. This final of three articles discusses a new method of producing hollow shafts for power transmission. As a result, we obtain a more uniform and dense metal. Dangerous biggest heavy duty hammer forging process, fastest hydraulic steel forging machine duration. A new analysis model is presented to simulate both the cold swaging process and hot radial forging process. For instance, it can conduct necking of the tube ends before tube hydroforming process and internal gear machining process. It is usually referred as hot pressing, and is carried out either using hydraulic presses or mechanical crank type presses. Note that, for large quantities, forging is more economical.
Forging is often classified according to the temperature at which it is performed. Forging is used in manufacturing and is a way of shaping metal with c. For quick adaptation to industry, the method is conceived such that the process can be carried out using conventional forging equipment. Process operations graphical depiction of process steps. Pdf finite element analysis of tube swaging and radial forging. It can also be used for manufacturing internal profiles for. Lets make a swage press if this is your first visit, be sure to check out the faq by clicking the link above. This process serves as the initial processing step for forging of parts such as connecting rod, crank shaft etc.
Swaging is used in the metalworking field, known as metallurgy, to serve a variety of. According to the swaging method and presence of mandrel, rotary swaging process of tubes includes four categories, infeed method without mandrel, infeed method with mandrel, recess method without mandrel and. With the help of a corresponding tool segment design, various part designs can be formed. We own manual swaging press djvu, epub, doc, txt, pdf forms. In cylindrical work the process of flanging a pipe section is to turn an edge out on the end of the pipe. It is basically a hot working process in which the work piece is heated up to plastic stage and the force is applied by manually or by press according to the requirement.
Paumac tube forming handbook was designed to be a useful guide for the buyer, engineer or designer whose responsibilities include the specifications and procurement of metal tube assemblies. Modeling conditions in this paper, the metal forging simulation software transvalor forge 2011 2d was used to simulate the joining process of tubetube parts by rotary swaging method, and also the pullingout process of the joined tubes. Ring diameters can be anywhere from a few inches to 30 feet. Swaging is usually a cold working process, but also may be hot worked. In manufacturing industry, swaging is usually performed as a cold working process. Recess swaging method for manufacturing the internal. Dec, 2017 the heavyduty rearaxle shaft and piniongear shaft are used to demonstrate how the differentialheatingbased forging process may be applied to create hollow shafts with flange or cone features.
It is one of the oldest metalworking arts with its origin about some thousands of years back. Swaging is a process that is used to reduce or increase the diameter of tubes. Dec 15, 2016 swaging machine for cartridge heaters. Closeddie forging is the term applied to all forging operations involving threedimensional control. We are in the process of installing a huge upgrade to our site. Forging process animation by basic engineering duration. The wire is then taken to a cold press for swaging. This can be further expanded by placing a mandrel inside the tube and applying radial compressive forces on the outer diameter. Swaging is the actionoriented process for shaping a swage. This post is in continuation with last weeks post on the finite element analysis model of rotary forging process of a wheel hub bearing assembly. In hot forging process, forging is carried out at a temperature above the recrystallization temperature of the metal which means at the temperature. In ancient times, people employed forging for making coins, jewelry, weapons, forging is a deformation processing of materials through compressive stress. This tube swage process is done mostly with aluminum, copper or thin wall steel. Seamless rolled ring forging is typically performed by punching a hole in a thick, round piece of metal creating a donut shape, and then rolling and squeezing or in some cases, pounding the donut into a thin ring.
Hot forging is the most widely used forging process. When a mandrel is used, the axial flow velocity at the sizing zone gets larger. The metal flow is most severe at the forging part, where the material flows. Cn101840447b finite element modeling method for predicting. Finite element analysis model of rotary forging for assembling wheel hub. Metal forming processes indian institute of technology. Swaging is used in the metalworking field, known as metallurgy, to serve a variety of purposes. Weldaloys rolled ring forging process delivers a better. What is forging process, operation, types, application. Swaging virtual labdayalbagh educational institute.
Repeat steps 1 through 8 to swage the opposite side of the bearing. It is designed for both experts and nonexperts in the forging industry. Pdf with the fast development of manufacturing industry, rotary swaging technology is applied. Unfortunately, the term rotary forging is sometimes used to describe the process that is more commonly referred to as radial forging, causing some confusion in terminology. Various forging operations hubbing process consists of pressing a hardened punch with a tip geometry into the surface of a block of metal hubbing force can be estimated from 3utsa uts is obtained from table 2. This process enables us to create bullets that are perfectly aligned to the dimensions and weight of the desired calibre. Cold tube swaging is relatively quick, inexpensive and chipless. Therefore, the infeed swaging process is often utilized at the occasion. Hot forging process and its applications steel forging. It is basically a hot working process in which the work piece is heated up to plastic stage and the force is applied by. Rotary forging rotary forging, or orbital forging, is a twodie forging process that deforms only a small portion of the workpiece at a time in a continuous manner. Rotary swaging forming process of tube workpieces sciencedirect.
Rotary swaging forming process of tube workpieces core. Pushpull control rods, elevator controls, strut assemblies, helicopter drag struts. An effect of work hardening during swaging process is shown in table 3. The site may be down here and there and upon completion will have an entirely new look for a few days. Stresses beyond yield strength of the workpiece material is required. Swaging swaging is a process that is used to reduce or increase the diameter of tubes. Rotary swaging is an incremental cold forming process and has an important. Roll forging roll forging or roll forming is a forging technique that utilizes opposing rolls to shape a metal part. We aim to provide you the basic and advanced foundation of metal forging.
A swage is the shaped tool used to transform an objects shape into the desired form by bending or shaping. Some examples of shapes obtained by forging process. Forging is a metal working process in which useful shape is obtained in solid state by hammering or pressing metal. Most metal components intended to be forged are performed under hot forging. The forging done with the help of presses is known as press forging. In this paper, finiteelement simulations using forge 2011 3d has been carried out to investigate the rotary swaging process of tubes. The forging force is calculated by an empirical formula in the conventional rotary swaging industry, the calculation accuracy is low, and the change rule of the forging force along the rotary swaging technological parameters. Forging fullering,flattening,swaging learn and grow.