Introduction Basic Knowledge Forgings – Significance, Design, Production, Application Forgings – Significance, Design, Production, Application 1 Directory Page number Subject 30 Preface 4 - 80 Forging History 9 - 11 Production Statistics 12 - 14 Forging Materials 15 - 16 Grain-Flow 17 Tool Design and Profitability 18 - 19 Accuracy of Forged Pars 20 The most important forging processes 21 - 28 Forging Machinery 29 - 31 Automation 32 - 33 Pre-Forming 34 Ring Rolling 35 - 36 Open-die Forging 37 Special Process Hot Forging 38 Special Process Warm Forging 39 - 47 Cold Forging 48 - 52 Process Stages 53 Process Combinations 54 - 55 Tools 56 - 57 Heat Treatment 58 Surface Treatment 59 - 66 Quality Assurance and Material Testing 67 Machining Process 68 Forged parts in competition 69 - 81 Diversity of Forms 82 - 84 Applications 85 Diversity in Forging Technology 86 Optimization of Components NOTE: 87 - 90 Development Chain Please switch from standard view to 91 - 94 Simulation screen presentation to be able to 95 Sources of Illustrations and Information activate and use the links. 96 Imprint 97 - 101 Bibliography 102 Annex Forgings – Significance, Design, Production, Application 2 Preface Dear Readers, Ladies and Gentlemen, This presentation of the forging industry is designed to offer you an easily comprehensible insight into the highly interesting and, for the economy, tremendously important world of hot and cold forging. Even in the age of the Blackberry, IP-TV, Web 2.0 and all of the other colourful accomplishments that our modern world of the media presents us with every day, machine engineering and plant construction – which is dependent on forged components by massive forming – is and will remain one of the most important pillars of our present-day prosperity. Without high-strength, forged metal components, the economic and technical development that we have experienced over the last hundred years would not have been possible. Electricity and mobility in the form of motorised vehicles of all kinds are just two of the multifarious fields of application for modern forged parts. And also in the future, this technology will be used to an ever increasing extent: Thanks to worldwide economic growth in recent years, the export of forged parts from Germany to all parts of the world has been steadily increasing. Furthermore, the need to reduce CO2 emissions will also boost the demand for hot and cold forged parts. The use of renewable energy by way of wind and hydroelectric power plants, economical combustion engines with high combustion efficiency and low frictional losses, as well as efficient dual clutch transmissions are merely a few of the many examples of environment protection which would be impossible without forged components. To enable the development and application of these often very complex and, technically speaking, highly demanding components, an increasing use of cutting edge computer technology and simulation software is being made in this branch of the industry. This presentation “Basic Knowledge: Forgings – Significance, Design, Production, Application” is an “open” PowerPoint File. This means that it is possible for you to take elements from it for teaching purposes for your own presentation. By using the search function in PowerPoint, you are able to find the terms you need from the presentation in a few seconds. Besides the clear, summarised texts on the individual pages, many pages also show more detailed, full text descriptions that will provide you with further background information. Via directory you are able to switch within the subjects. Hagen, 01/04/2011 Dr. Stefan Witt Chairman of the Board Industrieverband Massivumformung e. V. German Association of the Forging Industry Back to directory >> Forgings – Significance, Design, Production, Application 3 The art of forging is already 6000 years old Forging is one of mankind's oldest technological processes. In 4000 BC metals were already being worked by smiths The first copper-alloys appeared around 2500 BC - we call this the Bronze Age Sketch from the pictures in the grave of Rechmiré, vizir in the 18th Dynasty (ca. 1450 BC) Back to directory >> Forgings – Significance, Design, Production, Application 4 Forging through the ages I Between 700 and 500 BC iron replaced bronze. The smelting of the iron ore and the forging process were one unit until the 13th or 14th centuries. Mediaeval smelting furnace with accompanying smithy. The furnace and the smith's fire both used charcoal as fuel in those days. Back to directory >> Forgings – Significance, Design, Production, Application 5 Water and steam replace muscle power Water-powered iron hammer (ca. 1780) Steam hammer "Fritz" in Essen (ca.1860) Back to directory >> Forgings – Significance, Design, Production, Application 6 The start of drop forging The smiths of those days used hammers driven by transmission shafts to produce a wide range of forged parts for the railways, for the car industry and for agricultural machinery View of the production area of the Schmiedag Range of products of the Schöneweiss company in Hagen (ca.1910) drop-forging works (ca.1910) Back to directory >> Forgings – Significance, Design, Production, Application 7 Development of forging technology The development of drop forging made possible: - increasing batch sizes for the automotive industry - further development of and specialization in steel types - new technologies for tool production - development of new machine types, new production processes and combinations of processes, and automation View of a production facility with a linked automated forging line Back to directory >> Forgings – Significance, Design, Production, Application 8 Production figures - German forging sector Production of forgings in 2010 Manufacturing group Production in '000 tonnes Proportion in % Drop forging industry 1280 65 Flange manufacturers 68 3,5 Pipe-fittings producers 95 4,8 Cold-forging manufacturers 175 8,9 Open-die forgers 350 17,8 Total forging production 1968 100 Almost two-thirds of the total forging output comes from the drop-forging sector. Back to directory >> Forgings – Significance, Design, Production, Application 9 Markets for forged products I More than a third of all forged parts are exported. The automotive sector, together with system producers (tier one suppliers) receives more than 80% of the total production. Mechanical engineering Others 5% 10% Export 35% System suppliers 36% Domestic 65% Cars 34% Trucks 15% Percentages of steel forged parts delivered in 2009, in tonnes. Back to directory >> Forgings – Significance, Design, Production, Application 10 Current status of drop-forging technology Germany is the number two producer world-wide. Production in 2008 was 3,000 000 tonnes. Back to directory >> Forgings – Significance, Design, Production, Application 11 Forgeable materials I All metals and metal alloys, with very few exceptions, are suitable for forging. There is a range of more than 2,500 types of steel from which to choose to achieve the most economical production process. Steel group Standard Mild steels DIN EN 10222-1 DIN EN 10250-1/-2 Heat-treating steels DIN EN 10083-1/-2/-3 Case-hardening steels DIN EN 10084 Nitriding steels DIN EN 10085 Steels for flame- and DIN EN 10083-1/-2/-3 induction-hardening Ball- and roller- DIN EN ISO 683-17 bearing steels High-temperature DIN EN 10269 steels DIN EN 10222-1/-2 Tough-at-low- DIN EN 10269 temperature steels DIN EN 10222-1/-2/-3 Stainless steels DIN EN 10222-5 DIN EN 10250-1/-4 AFP-Steels DIN EN 10267 Forming characteristics of various material groups Back to directory >> Forgings – Significance, Design, Production, Application 12 Forgeable materials II Steel group Standard Application Mild steels DIN EN 10222-1 Machine parts with low dynamic loading and tensile strength requirements DIN EN 10250-1/-2 Heat-treating steels DIN EN 10083-1/-2/-3 Machine parts and automotive components with higher dynamic or static loading such as steering knuckles, crank shafts, drive shafts and safety critical parts for automobiles and for use in cable cars and aerial ropeways. Case-hardening steels DIN EN 10084 Case-hardened gearbox and drive-line components such as gears, shafts, toothed Nitriding steels DIN EN 10085 parts and wear-resistant forming tooling. Steels for flame- and DIN EN 10083-1/-2/-3 Very high wear-resistance for chassis components, for tracked vehicles, conveyors induction-hardening for the mining industry, very large roller bearings with hardened tracks Ball- and roller-bearing DIN EN ISO 683-17 Special steels for hardened roller bearing rings and bodies. The steels achieve their steels very high hardness values by good through-hardening. High-temperature steels DIN EN 10269 High-alloyed steels for gas turbine engines, burners and industrial furnaces, forming DIN EN 10222-1/-2 tooling and dies. Tough-at-low- DIN EN 10269 Machine parts for use at sub-zero temperatures, automotive components for use in temperature steels DIN EN 10222-1/-2/-3 extreme conditions, springs and applications with high dynamic loading. Stainless steels DIN EN 10222-5 Fittings for the chemical and food industries, components for marine use, fittings for DIN EN 10250-1/-4 the building industry, cutlery and household wares, screws and fasteners and wire ropes for use in damp conditions. AFP-Steels DIN EN 10267 Application as with heat-treated steels but more cost-effective for engine and chassis components such as connecting rods, crankshafts, steering components, drive shafts and axles. Back to directory