Analysis and preform design for long press forgings with non-planar parting surfaces

Karagözler, Ahmet Barış
In industry, a wide variety of parts are produced by press forging. Press forging generally requires sequential forming of workpieces through a set of preforming stages before the final stage. The design of preform dies affects die and product cost and quality. To ensure complete filling of the die at the final stage, companies in the forging industry commonly add extra material to the original workpiece volume and accordingly design the perform dies by the help of their experience. However, this method reflects extra costs in the form of wasted material as well as the need of early revision of the dies due to rapid die wear. In this study, press forgings, which require dies with non-planar parting surfaces have been examined. A method for the design of preform dies for this kind of complex shaped parts is proposed to reduce material wastage and cost. The press forging process for industrial parts is analyzed by using a commercially available finite volume analysis software for an application in a forging company. The appropriate preform design has been realized for a particular forging using the proposed method. The preform die has been manufactured and put into the production line in the company. As a result of this study, considerable amount of reduction in the usage of material has been achieved with a reasonable number of forging operations.


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Siddique, Muhammad Ahmad; Gökler, Mustafa İlhan; Department of Mechanical Engineering (2014)
In the forging industry, one of the main challenges is the reduction of setup change time which is non-productive time on the forging press. Long non-productive time reduces efficiency and affects profitability of the forging companies. In this thesis study, firstly setup change activities on the 1000 ton forging press of a forging company are observed and analyzed. With the help of these observations, it is seen that the new die holders with cassette holders and the new cassettes are required to reduce the...
Citation Formats
A. B. Karagözler, “Analysis and preform design for long press forgings with non-planar parting surfaces,” M.S. - Master of Science, Middle East Technical University, 2003.