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The diploma thesis deals with suggestion of low alloy 14220.0, produced by solid forming. This suggestion is based on the size of series that contain 100 000 pieces a year. The essay contains knowledge refering to drop forging technology and comparison with existing technologies. Two suitable variants of production were assessed, these variants are drop forging with hammers and vertical forging press. Both theories were theoretically analised in order to describe given technology. The analysis also contains calculation and suitable machine choice. Drop filling on vertical forging presses was chosen because of forging type. Furthemore forging proposition was treated including production technique. The chosen variant contains calculation, suggestion of a die, machine that was used and suggestion of flash trimming. For suggested technology was chosen vertical press LZK 3150 B. Its producer is Šmeral a.s. Brno. This project also contains technical drawings of the given component, forge, dies and phase of forging.

PFEIFER František: Production of support by solid forming. A Graduation Thesis of Master´s Studies, the 5th Year of Study, the School-year 2008/2009, FSI VUT Brno, Department of Machining, May 2009, Pages No. 94, Pictures No. 37, Tables No. 3, Appendixes No. 13. The Graduation Thesis, elaborated in the framework of engineering studies, presents the production technology of support component from steel ČSN 12 010. A material is a rod of the 130 – 251 ČSN 42 5510. A yearly production is 95 000 pieces. Based on the studies of possible production technologies was proposed the technology of production by the vertical forging press LMZ 6500B (Šmeral Brno a. s.) with a nominal forming power of 65 MN, flash and pellicle trimming on a trimming press with a nominal power of 8 MN. For this option, the required technological calculations, the design of the die, the specification of production machines and a simulation forming process which is made in the software QFORM have been carried out.

This master´s thesis submit a project of technology of production of gear wheel the way of drop forging. A part is made of steel 14 220.0 (16MnCr5). A semi-product is a stick of parametres o75 - 211 ČSN EN 10060, with a production of 130 000 pieces a year. Technological process of drop forging are worked up based on a study presented in technical literature. A forging will be working up on a vertical forging press LMZ 1600 A made in Šmeral Brno, Inc. For this option, the required technological calculation, drawing documentation and forming process simulation which is implemented by way of the software FormFEM have been carried out. Technical and economical evaluation of the component technology producing is brought in as a conclusion of the thesis.

This diploma thesis deals with project of shaft manufacturing using drop forging technology. This technology is manufacturing using cubic forming on vertical forging press. Work includes detail data for working out technical drawings of suggested component. Thanks to modification of parameters and forging a whole we reduce material waste which is compared to turning technology. Production process is adapted to established production process in company Kovarna ZETOR Brno. Further the work includes cost price of one forging from the set of 30 000 products a year. The work also contains background research of drop forging technology, technical drawings, production process list and simulation outcome for drop forging of the suggested komponent by software FormFEM.

In automotive industry, forgings are widely used especially in safety related applications, typically suspension, brake and steering systems. In this study, forging process of a steering joint used in heavy vehicles has been examined. This particular part has a non-planar parting surface and requires a series of operations, which includes fullering, bending and piercing on a forging press. Forging companies generally use trial-and-error methods during the design stage. Also to ensure complete die filling at the final stage, extra material is added to the billet geometry. However, the forging industry is becoming more competitive finding a way to improve the quality of the product while reducing the production costs. For this purpose, a method is proposed for the design of the preform dies to reduce the material wastage, number of applied strokes and production costs. The designed operations were examined by using a commercially available finite volume analysis software. The necessary dies have been manufactured in METU-BILTIR CAD/CAM Center. The designed process has been verified by the experimental work in a forging company. As a result of this study, remarkable reduction in the flash, i.e. waste of material, has been achieved with a reasonable number of forging operations. In addition to forging of the steering joint, forging of a chain bracket, which has bent sections with planar parting surface, has also been observed and analyzed during the study. An intermediate bending stage has been proposed to replace the manual hammering stage and satisfactory results have been observed in simulations.

There is a strong need in forging industry to reduce waste of material, improve quality, and reduce cost of forgings. About 30% of the material is wasted during conventional closed-die forging. Therefore, in order to reduce the cost of forged products and to obtain near-net or net shape parts, new forging methods should be applied. Precision forging concept is a cost-effective way to produce net-shape or near-net shape components. In recent years, there has been an increased interest in the production of gears by the net-shape forging technique. This has specific advantages over the traditional manufacturing processes of cutting gears such as hobbing, turning, and grinding including savings on cost and raw material, increased productivity, and gears with higher dynamic properties than conventionally cut ones. In this study, precision forging of a particular spur gear has been investigated. The precision forging die set has been conceptually designed and modeled in a computer aided design environment. The forging process of particular spur gear has been simulated by using a commercially available finite volume program. After the successful simulation results, the prototype die set and the tube-shaped billets were manufactured. The real-life experiments have been realized by using 1000 tons mechanical forging press available in METUBILTIR Research and Application Center Forging Laboratory. The results have been compared with the computer simulations. After the real-life experiments, it has been observed that the conceptual die design is appropriate and near-net shape spur gears are successfully obtained by the proposed precision forging die set.

Semi-hot or warm forging is an economical alternative to the conventional forging processes by combining advantages of hot and cold forging processes. In this study, a new forging process sequence and design of the preform die for a part which has been produced by hot forging are proposed to be produced by semi-hot forging. Thermo-mechanical finite element analyses are performed over the stages of forging process. The billet and the dies are modeled as elastic-plastic bodies. Effects of preform die geometry on the die stresses and the forging load are investigated using finite element method. Comparison of the results obtained by using two different commercial finite element analysis programs is done for semi-hot and hot forging temperature ranges. The forging temperatures are determined for the particular part and the experiments are conducted by using the 1000 ton forging press. The parts are produced without any defects and material wastage in the form of flash is reduced. The numerical results are also compared with the experimental results and a good agreement is achieved.

Forging is a metal forming process commonly used in industry. Forging process is strongly affected by the process temperature. In hot forging process, a wide range of materials can be used and even complex geometries can be formed. However in cold forging, only low carbon steels as ferrous material with simple geometries can be forged and high capacity forging machinery is required. Warm forging compromise the advantages and disadvantages of hot and cold forging processes. In warm forging process, a product having better tolerances can be produced compared to hot forging process and a large range of materials can be forged compared to cold forging process. In this study, forging of a particular part which is being produced by hot forging at 1200&deg / C for automotive industry and have been made of 1020 carbon steel, is analyzed by the finite volume analysis software for a temperature range of 850-1200&deg / C. Experimental study has been conducted for the same temperature range in a forging company. A good agreement for the results has been observed.