Forging Lab

Question 1

What is the objective of this lab?

Answer 1

1. Analyze the effects of cold forging on aluminum coupons by examining changes in their dimensions, hardness, and surface characteristics.
2. Evaluate the impact of varying forging forces on the deformation behavior and hardness of solid and hollow aluminum coupons.
3. Determine the influence of lubrication and annealing on forging performance, deformation, and hardness.
4. Investigate frictional effects in the forging process by estimating the coefficient of friction using reduction calculations and a ring compression test.
5. Establish relationships between key mechanical parameters such as stress, strain, and hardness through data analysis and regression techniques.

Question 2

What is the procedure for this lab? Part 1

Answer 2

Setup and Preparation

1. Prepare the specimens
   Remove the burrs and polish the top and bottom surfaces of all the specimens.
   Label each specimen and record the initial height, inner and outer diameter.
   Set aside one untreated solid aluminum coupon as a control specimen.
   Using Two ½ solid coupons annealed at 350°F

Clean the punch and die with alcohol. Reset the force reading to zero.
For coupon 1 (¾ OD hollow coupon)
Place it at the bottom die. Forge at max pressure (1150 psi) Record the press force reading and measure the final height, OD, and shape of ID.
Repeat for coupons #8 and #9.

For coupon 2
Clean punch and die.
Apply grease to the surfaces of coupon 2 (¾ OD hollow coupon)
Reset the force reading to zero
Forge the coupon at 1000 psi, record press force, final height, ID, OD, and shape of ID.

Question 3

What is the procedure for this lab? Part 2

Answer 3

For Coupon #3 (½” OD hollow coupon), forge at 550 psi, record measurements, and repeat for the remaining hollow coupons (#4 to #7) at 700 psi, 800 psi, 900 psi, and 1000 psi, respectively.

Teflon-Lubricated Forging (Coupons #10, #11, and #12)
Place Teflon tape on the top and bottom surfaces of Coupon #10 (¾” OD hollow coupon).
Forge at maximum pressure, then record the final height, OD, and observe the inner surface.
For Coupon #11 (untreated solid coupon):
Gradually increase forging pressure to 550 psi, 700 psi, 800 psi, 900 psi, and 1000 psi, recording measurements at each increment.
Repeat the gradual pressure increase for Coupon #12 (annealed solid coupon).

Control Specimens
Retain one untreated solid coupon and one annealed solid coupon as controls.
Hardness Measurements
Measure the hardness of all specimens at multiple points on the ends and along the diameter using the Rockwell-B scale or an appropriate softer scale.
Post-Lab Cleanup
Turn off the workbench and clean all equipment.
Remove any grease or Teflon from the dies.
Return all equipment to its designated place.

Question 4

What is the conclusion for this lab?

Answer 4

This lab explored the effects of forces, lubrication, and annealing on the deformation and hardness of aluminum during cold forging. Results showed that axial stress and strain followed expected patterns, with increased hardness leading to decreased strain. Lubrication, especially with Teflon, reduced the expected effects on deformation, while annealed coupons expanded more than non-annealed ones. Overall, the lab provided insights into how aluminum responds to different forging conditions, emphasizing the role of lubrication and annealing in material deformation.