Forging Part Design Workshop

Description

This course and the related material is designed to provide a working knowledge of the metal forging industry. Forging is the process by which metal is heated and is shaped by plastic deformation by suitably applying compression force. This is an introduction to Forging Design using Creo or SolidWorks where focus is on advanced modeling techniques where making changes is paramount. The class is intended for those designers and engineers who are designing forged parts using 3D parametric modelers such as SolidWorks or Creo. The bulk of time will be spent on the part design requirements imposed on the design engineer by the forging process. Topics covered will include the approach to modeling forgings, learning techniques where designers take a weldment and convert that assembly into a forged This training course is developed for seasoned users, who want to become proficient in learning forging part design and make changes quickly, setting one up to become an expert faster.

Topics

Rod Forging
  • Overview of the forging process complete with tooling and outside machining operations
  • 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
  • Learn to use a bit of surfacing, discuss its usefulness with forged part design
  • Die casting vs forging process with respect to cost and quantity
  • Techniques for converting multiple parts from a weldment into a cheaper, stronger forged part

Duration

16 hours / 40 hours

Prerequisites

General knowledge of SolidWorks, Creo or another parametric 3D CAD modeler imperative unless you are in purchasing

Projects

  • Motorcycle brake Lever
  • Pivot bracket
  • Harley rod
  • Motorcycle Kickstand: Convert from a weldment to a forging model
  • Convert welded assemblies complete with complex draft to a forged process
  • Use parameters, relations and underlying curve geometry to drive Creo or Solidworks geometry with respect to forged parts
  • Compare metal injection molding, powder injection molding, and forging
forge tool

Discussions

Forged Kickstart
  • Discuss the history of forming metals
  • Advantages and disadvantages with respect to cost and strength
  • Discuss alloys with respect forging
  • Compare cold forging, hot forging and warm forging
  • Discuss strengths and weakness of outsourcing
  • Discuss basic design elements for forged part design, i.e. holes, ribs, thin wall features, bosses, nominal walls, and fill
  • Discuss general rules for forging and how materials deform so designers can leverage flow for strength
  • Aircraft quality for high-stress forged parts
  • Discuss auxiliary operations such as specific surface conditions or shapes, not obtained by the regular processing operations
  • Flow stress with respect to deformation
  • Discuss heat treatment
  • Discuss ribs and the addition of gauge geometry for aligning for the CNC matching process forge part
  • Discuss Draft requirements with respect to material flow
  • Joining the Forging Industry Association
  • Discuss specification, purchasing quantities, tooling, ost reduction and cost of materials
  • Discuss making parts ready for the forging process that others created i.e. technique, Draft, strike direction
  • Discuss tips, tricks, and techniques for starting and completing forging parts using Creo or Solidworks
  • Learn to utilize Draft Check analysis tools correctly
  • Discuss chrome applications and other plating, painting or powder coating processes

Video Training Delivery System

Ask your Design Engine account manager about our Training Delivery System(TDS), an easy-to-follow guide for designers and engineers who want a supplement to this course.