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    Forging Defects

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    Ashraf Ali
    This document summarizes common defects that can occur during the forging process, including cracks, laps/folds, pitting, coarse grain wrinkles, flow-throughs, distributed metal defects, dents, underfilling, and rib/web defects. It provides examples and explanations of each type of defect, and discusses ways to prevent or minimize defects, such as forging at higher temperatures, stress relieving, lubricant management, and die design improvements.

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    Forging Defects

    Uploaded by

    Ashraf Ali
    2K views22 pages
    This document summarizes common defects that can occur during the forging process, including cracks, laps/folds, pitting, coarse grain wrinkles, flow-throughs, distributed metal defects, dents, underfilling, and rib/web defects. It provides examples and explanations of each type of defect, and discusses ways to prevent or minimize defects, such as forging at higher temperatures, stress relieving, lubricant management, and die design improvements.

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    This document summarizes common defects that can occur during the forging process, including cracks, laps/folds, pitting, coarse grain wrinkles, flow-throughs, distributed metal defects, dents, underfilling, and rib/web defects. It provides examples and explanations of each type of defect, and discusses ways to prevent or minimize defects, such as forging at higher temperatures, stress relieving, lubricant management, and die design improvements.

    Copyright:

    Attribution Non-Commercial (BY-NC)
    Download as PDF, TXT or read online from Scribd
    Download as pdf or txt
    2K views22 pages

    Forging Defects

    Uploaded by

    Ashraf Ali
    This document summarizes common defects that can occur during the forging process, including cracks, laps/folds, pitting, coarse grain wrinkles, flow-throughs, distributed metal defects, dents, underfilling, and rib/web defects. It provides examples and explanations of each type of defect, and discusses ways to prevent or minimize defects, such as forging at higher temperatures, stress relieving, lubricant management, and die design improvements.

    Copyright:

    Attribution Non-Commercial (BY-NC)
    Download as PDF, TXT or read online from Scribd
    Download as pdf or txt
    of 22

    Forging Defects

    S. Arvind Joshua Jaydev (20082203)

    Defects in Forging may Arise from:


    Inherent Defects while forging Faulty cuts in Forging Operations Improper Heating and Cooling

    Types of Defects in Forging


    1. Cracks 2. Laps/Folds 3. Pitting 4. Coarse Grain Wrinkle 5. Flow-through 6. Distributed Metal Defects 7. Dents 8. Underfilling 9. Void at Base of Rib 10.Push-through of Web under Rib

    1. Cracks
    Excessive working of a surface at too low a temperature leads to cracks Cracks may nucleate due to sulphur inclusions, etc. External cracks are most dangerous Cracks may appear at flash (if flash is too thin) Internal cracks may develop during Upsetting

    Inclusions leading to cracking

    Cavity in the centre of a cleavage facet. The small inclusion appears to have initiated cleavage fracture.

    Upsetting Forging

    Flash

    Combating cracks in Forging


    Forging at increased temperature Stress relieving before cutting off flash Hot-cutting of Flash Use concave die while upsetting.

    2. Laps/Folds
    Also called Fold-shut Occurs when two surfaces of a metal folds against each other without welding completely Metal may flow past a die cavity that has already been filled. May be due to Too small die radius, excessive chilling of high friction

    Example of Folding during Forging

    3. Pitting

    Pitting
    Pitting occurs because of incomplete cleaning of Die Die and workpiece should be free from scale while forging

    4. Coarse grain Wrinkle


    Wrinkling occurs during forging because the Billets contains coarse grains. These wrinkles fold into laps during forging.

    5. Flow-through

    Also
    Flow through may occur in cases where metal flows past the die recesses after filling. Die impressions are hence not completely filled. Maybe avoided by increasing temp. of stock Ensure lubricants are not trapped

    6. Distributed Metal Defects


    Loose oxides minimized die-slug contact Avoid too much lubricant

    7. Dents

    Dents are caused by


    Improper positioning of stock on die Throwing around the forging while it is still hot.

    8. Underfilling

    Underfilling
    Metal does not fill the recesses of the die completely Because of loose scale and lubricant residue that accumulates in deep recesses of the die

    9. Rib and Web defects

    A "peeling" lap forms in an aluminum rib-web forging as the corner of the die forces surface material ahead of the contact region. With a redesign of the upper die or preform, this type of defect can be prevented

    References
    Mechanical Metallurgy, G. E. Dieter http://www.forgemag.com Google Images

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