ABSTRACT

The study deals with the design and development of a die container in a flashless forging process. The basic configuration of a flashless forging process is the punch, counter punch and die container. In recent times, flashless forging has become the most economical form of metal forging process; it eliminates the occurrences of flash and requires no post machining process.

The major concern of this study is on the design features, which are categorized into billet design, tool design and the design process. The mild steel that was used as the die material was taken to the machine shop to be machined to an internal diameter of 51.41mm, external diameter of 66mm and the height of 75mm. The 2nd interface cylinder was machined to an internal diameter of 41.62mm, external diameter of 51.41mm with a bore height of 75mm. The 3rd interface cylinder was machined to an internal diameter of 33.06mm, external diameter of 41.62mm, with a bore length of 75mm. The 4th interface cylinder was machined to an internal diameter of 26.25mm, external diameter of 33.06mm with bore height of 75mm. observing the sequence of the cylindrical components machined, they could be easily be force fitted using a press machine.

The billet material which is the commercial pure aluminum stock of length 1000mm and 20mm diameter was cut into work pieces (billets) of length of 35mm using a power saw machine. Each billet was then machined on lathe by a facing operation to reduce the length to 30mm and to achieve smooth surfaces. These billet were used to compare the expansion obtainable in various dies (monoplex, duplex, triplex, quadruplex)

In the compression flow stress curve obtained, it is observed that more loads are required in the compression of aluminum billet in cold forging to bring about plastic deformation of the material. The billet was observed to have had a higher value of strain at subsequent load increment.