Course Duration: 16 hour
Tuition: $1,000 USD
Overview: The course and course material is designed to provide a working knowledge of the metal forging industry. The class is intended for those designers and engineers who are designing forged parts using a parametric modeler. The bulk of time in this workshop will be spent on the part design requirements imposed on the designer by the forging process. Covered in this workshop are such as approach to modeling forgings to learning techniques where designers take a weldment and convert that assembly into a forged part.
Prerequisites: General knowledge of Pro/Engineer or another parametric 3D CAD modeler helpful but not necessary.
Topics:
- Overview of the forging process complete with tooling and outside machining operations
- Forging is process by which metal is heated and is shaped by plastic deformation by suitably applying compressive force
- Discuss the progression of a forging process
- Open die drop hammer forging
- Impression die drop hammer forging
- Press forging, upset forging, automatic hot forging, and roll forging
- Powder mixes for compacting plus alloyed powder composed of two or more elements
Discussions:
- Discuss the history of forming metals
- Discuss the forging process and its specific history
- Advantages and disadvantages with respect to cost and strength
- Discuss alloys with respect forging
- Compare cold forging to hot forging and warm forging
- In detail steps of the forging process
- Discuss strengths and weakness of outsourcing
- Discuss basic design elements for forged part design. Holes, ribs, thin wall features, bosses, nominal walls, and fill
- Discuss general rules for forging and how material deform so designers can leverage flow for strength
- Aircraft quality for high stress forged parts
- Discuss auxiliary operations such as specific surface conditions or specific shapes not obtained by the regular processing operations
- Flow stress with respect to deformation
- Discuss heat treatment
- Discuss Draft requirements with respect to material flow
- Joining the Forging Industry Association
- Discuss specification and purchasing quantities or tooling specific to forging
- Cost reduction and costing
Pro/Engineer Specific:
- Watching your instructor, realize Draft in its many forms complete with examples of Split, Draft, etc
- Learn to use a bit of surfacing, discuss its usefulness with forged part design
- Learn to convert welded assemblies complete with complex draft to a forged process
- Discuss making parts ready for the forging process that others created i.e. technique, Draft, strike direction
- Techniques for converting multiple Pro/E parts from a weldment into a cheaper, stronger forged part
- Discuss tips, tricks, and techniques for starting and completing forging parts using Pro/Engineer
- Learn to use parameters, relations and underlying curve geometry to drive Pro/E geometry with respect to forged parts
- Discuss ribs and the addition of gauge geometry for aligning for the CNC matching process forge part
- Learn to use utilize Draft Check analysis tools correctly
- Discuss chrome applications and other plating, painting or powder coating processes
- Techniques for managing the Pro/E machining features
- Techniques for mounting your forged part to your CNC machine
- Prints, specification, and notes for forging detail drawings
Compare:
- Compare metal injection molding to powder injection molding to forging
- Forging process and product to die casting process
- Die casting vs forging process with respect to cost and qty
Tutorials:
- Motorcycle brake Lever
- Pivot bracket
- Harley rod
- Motorcycle Kickstand
There is a great deal of HTML course material students take back with them from this workshop.
Click To View Images:
“Design For Forging”, “Forging Part Design”, “Design for Manufacturing”, “Design for Manufacturability”
