September 26–29, 2017
1111 Superior Avenue
Fourth Floor Conference Center
Cleveland, OH 44114
The FIA Theory & Applications of Press Forging & Die Design course provides forging-specific information about the various types of presses, as well as guidelines for designing tooling for forging and trimming. Taught by experienced academic and industry experts, the course is designed to:
• Broaden knowledge about press forging.
• Provide a basis for objective press selection.
• Furnish useful tool design guidelines.
• Compare approaches to press automation.
• Review guidelines for matching the press to the part in terms of size and operational features.
Topics covered during the 2017 FIA Theory & Applications of Press Forging & Die Design course include:
A review of terminology used in forging tooling classifications.
Forging Presses for Closed Die Forging
A brief history and overview of the three primary types of forging equipment: 1) Stroke-bound Machines (Mechanical Presses); 2) Force-bound Machines (Hydraulic Presses), and 3) Energy-bound Machines (Screw Presses, Hammers).
Press selection is extremely important, and this section will cover two of the many factors which should be considered when selecting a press; factors for stroke restricted presses and for energy restricted presses. Also, two types of selection variables will be examined: part-dependent variables, and forger-defined variables.
Supporting Process Equipment
The object of this section is to make you aware of the effect on the press forging process by ancillary processes: raw material, raw material cutting and raw material heating. Although these are ancillary processes, which support the main effort of forging, it is important to treat them as individual processes having their own individual variables.
Induction Heating Principles for the Die Designer
This section will cover the basic benefits and operating characteristics associated with the induction heating process, of which die designers should be aware. It’s important the die designer understand what conditions can enhance or deter from meeting high performance production results, and should be able to judge or contribute to the improvement of day-to-day operations.
Die Design Calculations
Examples of formulae, along with explanatory sketches, for the most recurrent calculations that forging die designers use will be discussed. A few topics are: Calculation Method for Forging Force; Force and Energy Comparison; Shrinkage of Steel; Limits for Heading; Dies for Extrusion.
Quick Change Tooling Concepts
An analysis of quick die change principles covering the justification, savings, break down of involved elements, and variables for selecting a die handling system. A check list overview of “Planning to install a quick tool changing system?” will be discussed at the end of this section.
Trim Dies for Press Forging Applications
A trim die consists of primarily two parts, a trim punch and a trim blade, and the trimming process as we know it is the removal of the flash from the forged part. An analysis of the die set/combination die set and their different performances will be discussed.
Forge Bolsters for Press Applications
Bolsters are “tool holders,” and are anything designated as a support, or to sustain, to support, or to prop. In this section different types of bolsters, and the individual components, will be discussed.
Forging Press Automation Equipment
The three basic types of hot forging automation handling systems will be discussed in this section, and they are: robot systems; tong or gripper-arm systems; and walking beam systems.
Overview of Forging
This section will be an overview of the following units including: introduction to metal forming: overview of forming processes, and process complexities. Topics covered will be: Process Simulation; Die Failure Analysis; Optimizing Forming Load; Equipment Behavior; and Gear Blank Forging.
Die Materials for Press Applications
Since temperature is the single most significant variable that will affect die life and performance, tooling designers must carefully select the optimum material for the various die inserts, plugs, bolster plates, and die holders capable of withstanding the rigorous thermal and mechanical stresses inherent in the forging process. Techniques that may be utilized for the cost effective selection of die materials for forging press tooling are discussed in this section.
Manufacture of Close Tolerance Forging Dies
In this section, making dimensionally correct cavities made in impression dies will be discussed. Also the various considerations involved in making an accurate cavity from the viewpoint of a forging die designer, including; die sinking methods, finishing operations; die re-sinking methods, and die cavity shape verification.
Students are encouraged to submit a real-life problem from their company for the problem-solving session. A problem-solving report form will be sent to registrants in advance, providing an opportunity to submit a “problem” for consideration. A brief statement of the problem, material being forged, drawings of parts and/or dies, sample part (if size permits), and a description of effort (what has been tried that did not work) will be needed.
Dr. Chester J. Van Tyne
Colorado School of Mines
Kester D. Clarke, Ph.D., FIERF Professor
Colorado School of Mines
The workshop will be held in the FIA headquarters building, located at 1111 Superior Ave., Cleveland, OH 44114. The session will take place in the building’s fourth floor conference center.
These nearby hotels offer competitive rates:
DoubleTree Cleveland Downtown-Lakeside
Westin Cleveland Downtown
Hampton Inn Cleveland-Downtown
Cost to Attend (lunch included each day)
FIA member: $1,199
Fees are non-refundable after September 12, 2017, but substitutions are allowed.