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Die Design Parameters

The document discusses key parameters in die design for forging including: 1. The parting line is located at the largest cross-section of the part and may not be in a single plane for complex shapes. 2. Flash and gutters allow excess material to flow out of the die to prevent excess forging loads and are usually 3% of maximum thickness. 3. Draft angles make part removal from the die easier, with internal angles larger than external angles. 4. Fillets at corners ensure smooth metal flow and improve die life.

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236 views3 pages

Die Design Parameters

The document discusses key parameters in die design for forging including: 1. The parting line is located at the largest cross-section of the part and may not be in a single plane for complex shapes. 2. Flash and gutters allow excess material to flow out of the die to prevent excess forging loads and are usually 3% of maximum thickness. 3. Draft angles make part removal from the die easier, with internal angles larger than external angles. 4. Fillets at corners ensure smooth metal flow and improve die life.

Uploaded by

punkhunk
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
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Download as PDF, TXT or read online on Scribd
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16

DIE DESIGN PARAMETERS

1. Parting Line
-

is at the largest c/s of the part

is a st. line at centre for simple shapes

may not be in a single plane for complex shape

2. Flash and Gutter

Flash material is allowred to flow into a gutter

Prevents unnecessary increase of forging load (because of excess/ extra flash)

Guidelines for flash and clearance between dies:


-

3% of max. thickness of the forgings

The length of the land = 2 to 5 times the flash thickness

3. Draft Angles
-

For easy removal of forgings from the die

Similar to draft in casting design

Internal draft angles are larger 7o- 10o

External draft angles are smaller 3o- 5o

4. Fillet : It is a small radius provided at corners.


-

To ensure smooth flow of metal into die cavity

17

To improve die life

As a general rule, should be as large as possible

Small fillet radii lead to;

Improper metal flow

Rapid wear of die

Fatigue cracking of dies

5. Die material : requirements are

Strength and toughness at elevated temperature

Hardenability and ability to harden uniformly

Resistance to mechanical and thermal shocks

Wear resistance to resist abrasion wear due to scales present on work piece
Selection of proper die material depends on :

Die size

Composition and properties of work piece

Complexity of shape- no of performing steps

Forging temperature

Type of forging operation

Cost of die material

No. of forgings required

Heat transfer from work piece to dies

Die materials used:

Tool and die steels with Cr, Ni, Mo, Va


Die Manufacturing: It consists of the following steps:

-- Initially castings

then forged

finally machined and finished to required shape and surface finish

18

Material Flow Lines in Forgings:

Fig. Material Flow Lines

The deformation produced by forging gives a certain degree of directionality to the


microstructure of the work material.

Due to this, second phases and inclusions are oriented parallel to the direction of
greatest deformation.

When magnified, this appears as flow lines or fiber structure, a major characteristic of
all forgings.
Limitation of flow lines:

Flow lines (fiber structure) lead to lower tensile ductility and lower fatigue properties in
the direction normal to it ( in transverse direction).

Hence optimal balance between ductility in longitudinal and transverse directions is


very essential. (Deformation limited to 50% to 70% reduction in c/s area.

Source : http://elearningatria.files.wordpress.com/2013/10/mp3_unit3_forging_final.pdf

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