In preparation of forging a large gear blank, a 1045 steel billet of 200-mm diam
ID: 1842840 • Letter: I
Question
In preparation of forging a large gear blank, a 1045 steel billet of 200-mm diameter and 400-mm height is upset at 1000 degrees Celcius to a 100-mm thick "pancake." As a part of your process design... graphite lubricant is chosen
a) make a sketch of the operation
b) calculate the average die pressure if a hydraulic press with 3 m/min speed is used.
c) calculate the force required to forge the part
d) what changes in die pressure and forging force would occur if the upsetting process is conducted at room temperature?
Explanation / Answer
All the dimension are given. We are now calculate the unknown dimension.
Step 1. The volume of workplace before forging = the volume of workplace after forging. With the help of this we can calculate the remaining parameter of after forging.
Step 2. Minimum initial force required = yield stress of material * initial cross section area
Now with this find final area of work piece.
Step 3. Then take average of both the forces to find average force minimum.
Step 4. Find actual force required(f) act = (f) min/ efficiency of forging.
Generally varied between 50%-60%.