By,

Sri Krishna Chaitanya Kakarala

Nitin Chinnamaraju

Forging is a manufacturing process involving the shaping of

metal using localized compressive forces.
Forging is one of the oldest known metal working processes.

Mainly, the principle behind the

forging processes can be classified
into the following 3 main
categories

All the forging processes can be processed at various

temperatures, however for the convenience the temperatures at
which Forging are classified into 2 main categories. They are:
1) Hot Forging
2) Cold Forging

Less compatible (1 Main Cylinder and 2

Returns cylinders)

More Energy losses

Not applicable for more than 1500 Tons

PRESSURE INDICATES WORK LOAD [ P= F/A ]

P in Psi ; F in pounds ; A in square inches

COMPUTING PISTON AREA

WORK AND POWER

HORSEPOWER AND TORQUE

The following are the calculations made for design

criteria:
Pressure = 350bar (Assumed)
Force = 3000Tr (Required)
Stroke length = 1600mm (Required)
Up Speed = 140mm/Sec (Required)
Down Speed = 120mm/sec (Required)
Pressing Speed = 65mm/sec (Required)

For the above assumed values the factors

considered for the press are:
Main cylinders = 3 No.
Return cylinders = 4 No.

Each main cylinder has a capacity of 1000Tr force.

Hence, for single cylinder we have,
Force = 1000Tr = 1000*103 kg
Pressure = 350bar
Area = (/4) * d2
Force = Pressure * Area
1000 * 103 = 350 *(/4)* d2
d2 = (1000*103*4) / (350*pi)
d2 = 3637.827
d = 60.314 cm
d = 603.14mm (per cylinder)

Pressure = 350bar
Force = Total dead weight
= Weight of casting + Mass of ram cylinder + Weight of
top die + 25%
Weight of the casting = 120Tr
Volume of main ram is, V = (/4) *(d2) * L
= (0.78539) * (603.14)2 * 1600= 0.457m3
Weight of the ram = 0.457 * 7000
(Ram is made of cast iron whose density =7000kg/m3)
= 3564.6Kg = 3.564Tr
Total weight of three main rams = 3 * 3.564= 10.692Tr
Weight of the top die = 0.5Tr

Dead weight = 120 + 10.602 + 0.5= 131.192Tr

25% of the dead weight = (25/100) * 131.192
= 32.797Tr
Total dead weight = 131.192 + 32.797
= 163.989Tr
Total dead weight acting on each cylinder = 163.989/4
= 40.99Tr
Force= Pressure * Area
40.99*103 = 350 * 106 * (/4) * d2
d2 = (40.99 * 103 *4) / (350 * 106*)
= 12.2112cm
= 122.112mm

The assumed values for calculating discharge are,

Up Speed
= 140mm/sec = 14 cm/sec
Down Speed
= 120 mm/sec = 12cm/sec
Pressing speed = 65mm/sec = 6.5cm/sec
Discharges are calculated at three levels:
Down Speed
Q= A*V down
= (/4) * d2 * (12* 60)
= (0.78)* (60.3)2 * 12*60
= 2056160.453cm3/min
= 2056.160453 lit/min

Up Speed
Q
= A * V up
= (/4) * d2* (14*60)
= (0.78) * (12.2)2*(14*60)
= 98194.8766cm3/min
= 98.1948 lit/min
Pressing speed
Q
= A* V pressing
= (/4)*(60.3)2*(6.5*60)
= 1113753.57909cm3/min
= 1113.753 lit/min

Horse Power = (Pressure* capacity of pump) /

(600*efficiency)
= (300*1012) / (600*0.90)
= 655.9259

An efficient system design is obtained.

Required output of 3000 Ton force is applicable by

the dies.

Negligible energy losses due to closed system.