THE TECHNOLOGY OF FORGING AND STAMPING FREE FORGING AND VOLUME STAMPING

• Document Type: CREST
• Collection: General CIA Records
• Document Number (FOIA) /ESDN (CREST): CIA-RDP81-01043R001900100003-3
• Release Decision: RIPPUB
• Original Classification: K
• Document Page Count: 179
• Document Creation Date: December 23, 2016
• Document Release Date: April 16, 2013
• Sequence Number: 3
• Publication Date: January 1, 1956
• Content Type: REPORT

Declassified in Part - Sanitized Copy Approved for Release 2013/04/16: CIA-RDP81-01043R001900100003-3
? AIR TECHNICAL INTELLIGENCI.
TRANSLATION
TITLE (UNCLASSIFIED)
THE TECHNOLOGY OF FORGING AND STAMPING FREE FORGING AND VOLUME
STAMPING
BY
E. A. SATELI
FROM
SPRAVOCHNIK MASHINOSTROITELYA, V SHESTI TOMAKH
VOL. 5, 1956
pp. 89-179
eit.iy_teA)
STAT
Declassified in Part - Sanitized Copy Approved for Release 2013/04/16: CIA-RDP81-01043R001900100003-3
Declassified in Part - Sanitized Copy Approved for Release 2013/04/16: CIA-RDP81-01043R001900100003-3
CHAPTER II
THE TECHNOLOGY OF FORGING AND STAMPING
FREE FORGING AND VOLUME STAMPING
The Quality of Forged and Stamped Products
The Effect of Forging upon the Macrostructure
Hot mechanical treatment (forging
a)
b)
Fip.1 - The Macrostructure
of Steel
a) Casting; b) Forging
or rolling), of a cast ingot will deform and
change its original structure (Fig.la)
by drawing out its crystallites in the
direction of the flow of the metal.
The result will be the formation of a
so-called fibrous macrostrUcture
-4 (Fig.lb); first in its central zone,
and later, with the increase in the
degree of forging*, it will be formed
in its peripheral zone.
In the central zone, the fibrous
structure is formed when the degree of
forging has a value of 2 - 3. At such
rate of forging, the column-like dend-
* The degree of forging is the ratio of the area of the original cross section
of a cast ingot to the area of the cross section of the forging made from it.
173
STAT
Declassified in Part - Sanitized Copy Approved for Release 2013/04/16: CIA-RDP81-01043R001900100003-3
STAT
Declassified in Part - Sanitized Copy Approved for Release 2013/04/16: CIA-RDP81-01043R001900100003-3
?
?
?
rites in the peripheral zone will undergo little change in their original direction.
When the degree of forging is raised to h - 6, the deformed dendrites of the
peripheral zone are still
Fir.2
present and they are not in the direction of the flow of
A fibrous macrostructure
the metal. Only when the degree of forging
reaches the value of 10 and higher, forged
steel will acquire a fibrous macrostructure
along its entire cross section (Bib1.15).
Therefore, when evaluating the mechanical
properties of a forging, consideration should
be.given to the direction, i.e., along and
across the fibers of the sample under test.
of forged (rolled) steel has a fairly stable forma-
tion. It cannot be destroyed by heat treatment and the pressure following the
heat treatment may possibly only change the straight-line direction of the fibers
to curves, (Fip.2).
The Effects of Forginp on the MecYanical Properties (Bib1.15)
Hot forging will practically have no residual effect upon such properties as,
strerpthar;
(r fluidity frir and proportionality a- pts . It means, the above properties
will remair the same for samples subjected to the same heat treatment resulting in
the same microstructure, although forged at different degrees of forging.
Forpinp of a cast ingot will produce a considerable residual effect on such
properties as impact viscosity an, cross
sectional shrinkage (narrowing) .q,, elonga-
tion 6 and endurance 0_1.
The following should be noted concerning the'above properties: increasing the
degree of forging to 10 will notably improve these properties in longitudinal
(along the fibers) samples and this improvement will remain stable. On the other
hand, as a rule, the an 6,1v, and a-1 in transversal (across the fibers) samples
174
Declassified in Part - Sanitized Copy Approved for Release 2013/04/16: CIA-RDP81-01043R001900100003-3
Declassified in Part - Sanitized Copy Approved for Release 2013/04/16: CIA-RDP81-01043R001900100003-3
?
?
b- the grade or t*,c steel Ind the size or the piece (see lLter in text).
:ot forginr of a steel which, Ls casting, contaiLs in its microstructure
come!tite zet or 1Lrge cirbide grains, will favorably affect the (pant- of the
finished product by destroying the net and
erti by pulverizing the carbides.
Cold forging will physically solidify
(harden) the metal; heat treatment will
relieve it (see Chapter XI).
ic=r1
4'14
11,1;
i;
j
Fig.3
a)
Fig.h
Fig.5
C)
Preparatory Lethods and Their Effect on
the Finishnd Product
To obtain the best mechanical proper-
ties, the following conditions are to be
maintained: 1) a degree of forging best
suited for the piece to be forged (see
earlier in text); 2) the direction of the
fibers should coincide with the direction
of the maximum normal stresses to which
the finished product will be subjected in
performing its. duty. If this is impossible
adjusting the mandrill, upsetting, or any
other means should be used to diminish
the discr6pency in the mechanical proper-
ties along and across the fibers; 3) the
direction of the fibers should be cobrdi- '
nated with the contours of the piece, the
fibers should not cross each other; h) the axial zone of the ingot should not: be
displaced or the surface of the forging; 5) tl-ermomechanical Conditions best for
STAT
? 17
Declassified in Part - Sanitized Copy Approved for Release 2013/04/16: CIA-RDP81-01043R001900100003-3
Declassified in Part - Sanitized Copy Approved for Release 2013/04/16: CIA-RDP81-01043R001900100003-3
the forging should t.e observed (see later in text).
? The above requirements may not be strictly adhered to in oases where best me-
? _
ch3uical properties are rot essential and cost ard productivity are more importdnt.
The field, dealing with the effect of technological processes in forging on
the quality of the finished product, was
(
????
?
?
tackled and broadly covered by Prof.K.F.
1-
--r- r:
K.F.Orachev.
Examples; 1. Figure 3a shows a bolt
0 -7-
cut from a rod. The macrostructure of its
head is unsatisfactory - the normal
Fir.6 stresses are directed across the fibers.
Also, the stem of the bolt is formed from
the central zone of the rolled rod, a zone having qualities of a lower grade. The
bolt in Fig.3b is made by having its stem drawn out. The direction of its fibers
is more favorable. Making the bolt (Fig.3c) so that its head is pressed down from
a rod of the same diameter as its stem,
b)
/ produces the most favorable difection-of
\
1 , F , its fibers.
1 I
Y A
I -1)
?
Fig .7
1) Axial zone of stock
Example 2. The gear, shown in Fig.4a
is cut out from a rod. The normal stresses
in the teeth (1) will be directed unfav-
orably - across the fibers. In a-gear,
stamped out from a strip (Fig.0), the
direction of the.fibers in relation to
the direction of the normal stresses will
vary for each tooth. Tooth (1) operates along the fibers, which is correct; while
tooth (2) operates across the fibers, which is incorrect. A gear made by the upset
method (Fig.4c) will have most favorable directions for its fibers.
i;77
STAT
neclassified in Part - Sanitized Copy Approved for Release 2013/04/16: CIA-RDP81-01043R001900100003-3
Declassified in Part - Sanitized Copy Approved for Release 2013/04/16: CIA-RDP81-01043R001900100003-3
?
Example 3. The crankshaft in Fir.5a is forred without its wrist; the wrist and
the webs are formed bY cutting out part I. The result is: the fibers are cut and
the webs operate across the fibers. Tly havinr a crankshaft made by bendinr (Fir.5b)
the directior of the fibers will correspord to the direction of the normal stresses.
Example h. When a rirp, subject to internal pressures, is made by the method
of drawinr out with a mandril, (Fir.Aa), its fibers will be parallel to the axis
of the rirr, i.e., perpe-dicular to the directiors of the maximum stresses operatinr.
tanrentiall-r. On the other hand, the same ri--, but with the use of a tube exparder
durinr the forrirr ('-'ig.Ab), will lave fibers with a direction correspordinr to the
operatioral conditions of the ring.
Example 5. In a crankshaft forred from a plate after the split-cuttinr of the
crankthrow (Fir.'7a) and by drawinr cp't the erds, the axial zone will pass through
the middle of the webs, but ir the cr,t-kpin sections of the shaft the axial zone
will be displaced ir relation to their axis and will appetr partiall- on the surface.
This displacenet will not be produced ir sl aft forped by bendinr.
TEC:rMIOnICAL FU"DA77,"1-2:1L3 I" D7SIrrI1'r 17013.r7D KD STAI:7D PRODUCTS
r,eneral Informatior
The techrolopical co-sideratiors required when designinr products to be produced
b7- free forrirg ard hot stampirr differ sharply.
The choice between free forrirg ard stamping sl.ould be based upon mam, factors,
among which are: the possibilitr of .Lppl-Tinr (technicall'r) ore method or another,
nd the'adwtniages of ore metl-od over tnother with due consideration to the quality
of the product and the corfiruratior desired.'.
?or instance, free forritp m,ey be used in forginr pieces of ary weight, from
the smallest to the largest, for example 200 t. The weirht limit for stampinp
0 is 1-2t, with the bulk of stampinrs weirtinr up to 100 kp. Free forginr is rood
only for
nieces with plain confirura+ions, or lavirr excessive parts to be removed
STAT
178
^
Declassified in Part - Sanitized Copy Approved for Release 2013/04/16: CIA-RDP81-01043R001900100003-3
Declassified in Part - Sanitized Copy Approved for Release 2013/04/16: CIA-RDP81-01043R001900100003-3
?
mechanically in order to simplify the configuration. With stamping, a complicated
confiruration is feasible. As far as quality and precise surface is concerned,
these are low for Corrinr and high for stamping. When machining the piece, more
will be taker off when the piece is a forging and less, when it is a stamping. The
output forging is several times less than by stamping.
As a rule, forging of single pieces, or of a few pieces, is more advantageous
than stanpinr. On the other hand, for mass productior, stamping has by far greater
advantages.
For the average run in quartit-r, the selection is based upon the final cost of
the finished product, thus, in many cases, despite the hirher cost of operation,
the use of less material and less machinirg thereafter, make stamping cheaper. Even
when the quantit7 amounts to a few dozens, stamping may prove to be cheaper than
forrinr.
Tec'rolorical Consideratiors in Desi- mi- Products Fabricated hr Free Forging
The design of the stock to be fabricated by free forging should also be
coordinnted with the technologist. This, to insure maximum mechanical properties,
minimum wastage and ease of operation not only in the process of forging but also
in the finishing operations thereafter.
The most desirable forms for such products should be simple, symmetrical,
struipht and smooth and should be hound by plane or c-rlindrical surfaces. The more
the configuration of a forrinr is complicated, the higher the cost of its fabrica-
tion.
Certain portions of a forrinr may prove to be unforreable by the method of free
forging. In cases of this kind, surplus material must be added to the stock in
order to simplif- the configuration, with the subsequentremoval of the surplus
material mechanically, or by torch.
For example, the forging shown in Fir.8 cannot be produced by free forging
-1/0kT
179
Declassified in Part - Sanitized Copy Approved for Release 2013/04/16: CIA-RDP81-01043R001900100003-3
Declassified in Part - Sanitized Copy Approved for Release 2013/04/16: CIA-RDP81-01043R001900100003-3
without the use of surplus material. The confiruratiop shown in 1'i1-.9 has to be
Lhe for Ike desi-r.
4_17 I
ri),Irg i
2, JF,?
cicz, * 8 / .e -: ' ,..1
..
..... 4, ...
11. i f .1--1--1
40 RI 1 1
40.- ---30'0-.4-Zal 5C0 --1-,Tc--...V -- 4...1
Fir.e
- 4 - -14
it
*.
150 .?IiJ
Cones (Fig.10a) and tapered s!apes (Fig.10b), especiall:- when slopinr only
slightly, should be avoided.
Consideration should be riven to the difficulty of producinp by free forring
"
01
b)
=3-
Fir.10
a) Correct; b) Undesirable
0
Fir .11
a) Correct; b) Undesirable
portions formed by the intersectior of c7lirdrica1 surfaces (7ir.11a), or formed
b- the intersectior of cylindrical with prismatic surfaces (Fir.11b).
In the handbook of small pieces; one-sided 'projections (Fir.10b) are more de-
sirable than two-sided (Fir.11b) projections.
Ribs are to be avoided. In most cases, ribs cannot be made by the method of
free ?forgi?!r ard the addin- of surplus material becomes necessary. ,So-called "ribs
of rigidity" in for-in-s are rot permissible (Fir.12).
Also to be avoided are "teats", plate-shape and other projections on the main
STAT
18p
Declassified in Part - Sanitized Copy Approved for Release 2013/04/16: CIA-RDP81-01043R001900100003-3
Declassified in Part - Sanitized Copy Approved for Release 2013/04/16: CIA-RDP81-01043R001900100003-3
?
body of ,! forging (Fig.13a), Ls well as projections inside fork-shaped corfigura-
tio:,L; ( 'T.13b).
f',erever the difference in cross-sectional areas is great, or where the config-
uration is complicated, it becomes neces-
sary to combine several pieces of a simp-
a)
Fig.12
a) Correct; b) Wrong
Li
1_. ler design, or weld several pieces to-
tether (Fir.14).
Another thing to consider is the pos-
sibility of getting a forging with a proper
direction of the fibers.
Technological Considerations in Designing Stamped Products
General Information: The geometrical shape of the piece should be such as to
make its removal from the form easy. The stamping dies consist of two parts (the
?L. _
) ,
i9
Figs.13 and 1/L
a) Correct; b) Wrong
^
- -:- 2250
a)
upper and lower halves)-. As a rule, they are open. Before the upper and lower
dies touch each other, the metal will flow out beyond the dies, thereby forming a
ring-shaped burr around the line of separation of the dies
.181
STAT
Declassified in Part - Sanitized Copy Approved for Release 2013/04/16: CIA-RDP81-01043R001900100003-3
Declassified in Part - Sanitized Copy Approved for Release 2013/04/16: CIA-RDP81-01043R001900100003-3
?
Stampirr presses (crank t7pe. for hot stampinr, screw-friction type, or hydraul-
ic t-pe) have dies usually consistinr of two parts: the dies are either open-type,
as in lamer presses, or closed type
??? /,,/;
5
Fig.15 - Formation of a 7';',1-r: a -
rinF of stampirr; b - Intermediate phase;
burr berins to form; c - 7.nd of stamp-
inr; 1 - Upper die; 2 - Lower die;
3 - Stock;./: - Burr
where a burr can be formed only at the
end of the operation. The appearance
of a burr is due to a clearance being
present between the lower and, the
enterinr into it, upper die. The lower
die is known as matrix, counter die,
die pot; the upper - as plunrer, punch-
inr die, etc. (Fir.16).
'or complicated corfirurations, the
matrixes are compounded from two or
more p-arts (Fir.17).
In a horizontal stamping press, the
-2
die consists of three parts: two mat-
rixes (stationary and movable) and a
plunrer. The separation of the lower
and upper dies is in two mutually
perpendicular directions.
If the stock is not to be stamped
all arourd, the problem of the separa-
tion of the .dies sholad-be"worked out
b-r the designer, as it may involve
such features as slope of the walls,
radius of roundness, etc.
In Table I are instructions dealing
with desirn of forrings to be stamped
- Closed Type Stamping Die
1 - aunrer; 2 - ratrix; 3 - Stock;
-
4 - Ejector
Fir:17 - Die with rovable ratrix
182
STAT - - -
Declassified in Part - Sanitized Copy Approved for Release 2013/04/16: CIA-RDP81-01043R001900100003-3
Declassified in Part - Sanitized Copy Approved for Release 2013/04/16: CIA-RDP81-01043R001900100003-3
?
?
Table 1
Selection of Correct Separation Su5faces (Bib1.8,36,7,1)
1. Make easy removal of the forging from the dies possible. Deep impressions in
the body of the stamping can be obtained only in the direction of impact. All
of the stamping's horizontal cross-sectional dimensions, above or below the
'parting line, should be less than thea cross-sectional dimension of this line.
Correct
, .
Wrong
2. The separation should be effected in the plane of the two greatest dimensions
of the product, i.e., so as to make the recesses in the die have the least
depth and greatest width (to help in filling up the recesses)
Desirable
Undesirable
,W4
?akimmik:
1!!!!!!!!!
Remarks: In some cases, separation is possible without strict adherence to the
requirements, e.g.,
a) if it saves metal, simplifies making of the stamping and cutting
dies, or permits use of fewer preliminary passes in the die.
b) if some surface (not to be stamped) should be flat and without a
stamping slope.
In line with requirement 2
IS allowed as an exception
183a
STAT
Declassified in Part - Sanitized Copy Approved for Release 2013/04/16: CIA-RDP81-01043R001900100003-3
Declassified in Part - Sanitized Copy Approved for Release 2013/04/16: CIA-RDP81-01043R001900100003-3
?
?
3n line with requirement 2 but surface F Is not in line with requirement 2
has stamping slope
fI
3. The separation of the dies should be so designed that the recesses in the upper
and lower dies should have the same contour (it will make it easier to detect
if any of the dies move)
? Correct
1
Wrong
4. The separation should be so designed that close contact with the surface is
made only by the vertical walls (having a stamping slope), but not by sloping
walls (it makes it easier to detect movements of the die)
Correct
Wrong
',/////.."
?
\\N. ?
5. Inasmuch as possible, the 'design should be such,, that the separation takes
place in a plane surface, and complicated surfaces are ,to be avoided (easier
to make the die)
Correct
?
183b
Wrong
STAT
Declassified in Part - Sanitized Copy Approved for Release 2013/04/16 : CIA-RDP81-01043R001900100003-3
Declassified in Part - Sanitized Copy Approved for Release 2013/04/16: CIA-RDP81-01043R001900100003-3
?
?
?
by open-type dies (forming rirg-shaped burrs) of hammers and presses. Other instruc?
tions in Table 1, deal with the selection of the separation of the die surface.
The side surfaces of the stock should be sloping (stamping slope) in the verti-
cal direction, i.e., in the direction of the impact. This will insure an easy re-
moval of the stamping from the dies. A true verticality of the walls may be secured
by mechanical treatment of the piece after.
Normal slope values for outer walls (that move away from the walls of the die)
and for inner walls (which, during the cooling hug the protuberances in the re-
cesses of the die) are shown in Table 2.
a=a14-y
Fir.18 - Method of Counterbalancing the Shearing Forces
ta_
Formal stamping slope; a- Increased stamping slive
a) Direction of the impact ID:, the hammer
For certain pieces, whose axis is bent, larger slopes aredesirable, as this
will allow the recessed portion of a die to have a location favoring the counter-
balancing the shearing forces, which arise during the stamping operation (see
Fig.18).
Uith angles y > 70, the above method (see Fig.18) will greatly distort the
stamping. _Therefore y should not exceed 70.
All surface ends should be rounded and sharp angles to be avoided.
Surfaces to be joined should be rounded, using as large a radius as practical.
The purpose is to avoid the necessity of having to use a greater than normal surplus
of material over the entire surface, which would be necessary to insure a correct
STAT
184
Declassified in Part - Sanitized Copy Approved for Release 2013/04/16: CIA-RDP81-01043R001900100003-3
Declassified in Part - Sanitized Copy Approved for Release 2013/04/16: CIA-RDP81-01043R001900100003-3
k
?
?
Table 2
Stampinr Slopes for Steel Stampirrs
(ib1.8, 3A, 1)
C)
d)
I a'
5
7
9
3
1-3
7
10
3
5
3-4,5
10
12
7
4,5-6,5
12
15
7
10
a) 6,5
15
15
13
12
f)
a) Oyer; b) Up to; c) Stamping without
ar e,4ector by 1-amrer,and mechanical
presses; d) Stamping with an ejector
by mecharical presses; e) Line of sep-
aration; f) LeFerd: p -Slope of inner
walls; a -Slope of outer wills
185
Table 3
Radii for Rounded 73rds of Surfaces
(9ib1.3(,, 1)
< 2
2_4J >4
< 2
2 - 41
>4
b) 15
1,5
1,1
2,0
4.0
5,0
8,0
15--25
1,5
2,0
2,.;
4,0
6,0
R.0
25--35
2,0
2,5
3,0
5.0
8,0
10,0
35-41
2,3
3,0
4,0
6,0
10,0
15,0
45-60
3,0
4.0
5,0
8,0
12,5
20,0
60 80
4,0
5,0
6,0
10,0
15,0
25,0
80--100
5,0
6,0
8,0
12,5
20,0
35,0
100-130
6,0
8,0
10,0
15,0
25,0
40,0
130 170
8,0
10,0
12,5
20,0
30,0
45,0
C)
a) Line of sepqratiOn; b) Up to;
c) Remarks: Radii R of the internal
(erterinp) angles should be rreater
than radii r of the external anrles
,(emerging), thereby avoidinr spoilage
(of clamps) and helping the dies to
remain firmly in place
STAT
Declassified in Part - Sanitized Copy Approved for Release 2013/04/16: CIA-RDP81-01043R001900100003-3
Declassified in Part - Sanitized Copy Approved for Release 2013/04/16 : CIA-RDP81-01043R001900100003-3
MEV
?
?
angle (Fir.19).
9esides this, the desirr.of a piece to be stamped ir open-tYpe dies, should be
ir conformitv with the instructions river in Table h.
a)
ceritotAr at
loritrii
Cort.tour of.
e4>?f-Trashed Fuca
Fir.19 - The Relation between the Amount
of Added Material to the Radius of
Roundness: a - Optimum relationship: rd
r - pn; h - Worst relationship: rd?
r - pn; where, rd is the radius of
rourdress of the finished piece; r is
the radius of roundness of the forrirr;
Pn is the normal amount of material to
be added; P is the ircreased amount
to be added
Fig.20
Instructions for 'Designing Pieces to be Stamped in Horizontal Forging Machines
Pieces with a great variety of shapes can be stamped in horizontal forging
machines (Fig. 20a, b, c). For best results, however, the stamping of pieces having
a regular form (Fig. 20a), or rotating bodies with projections and cavities Should
be performed in a horizontal forging press. Such pieces can be fabricated by a
horizontal forging press with more advantages than the hammer or press. In design-
ing pieces to be fabricated in horizontal machines - follow instructions given in
STAT
Table 5.
186
;. )
Declassified in Part - Sanitized Copy Approved for Release 2013/04/16: CIA-RDP81-01043R001900100003-3
Declassified in Part - Sanitized Copy Approved for Release 2013/04/16: CIA-RDP81-01043R001900100003-3
Talde
Instructions for Desirvirr Pieces to be 'orred h" :tamers with Open-T7pe Dies
1. Desirr witl the object to obtain A mininium difference ir cross-sectional areas
of differert portions spreld dim(' tle lerrth or the piece; avoid thin walls,
'Art ribs, fltrres, pro;:ectiors, teats, lour branches, and thin influxes in
contact with the plane of neparation (ease of operation, less spoilare and
savirr or material).
a) Sharp difference in rross-
sectional areas and small thickness
of the shelf will hamper the work,
will ircresse the wastare And will
not fill the firure.
b) A thin disc will cause a low firmness
of the dies, due to rapid cooling
and high deformation resistance.
Repeated heatinrs become necessary
to prevent the stpping beinr unfin-
ished. Will increase the amount
of rejects.
Piece 1, due to presence of thin and
tall ribs, carnot 1-se ohtaired 1)7
stamping without a subsequent mechan-
ical treatment. The raw piece
assumes shaPe 2.
d) In shape 1, the flarre has a larpe
diameter w'-ich hampers t:e stamping.
Designinr accordirr to shape 2 will
ircrease ti-e ease of operation 111
times.
e) A lonr and thin branch brings a larre
wastare of metal (75 or the weirht
of the forring) ard dr increase in
rejects due to 'irure being unfilled.
Thu thir influx 1, in contact with
the plane of separation, is subject
to br7akare, to beirr torn-off and to
cleavinr with the cold cuttinr-off
the blirrs; also to being dragred=in
inside the matrix with the hot cuttinr
of the burrs.
Declassified in Part - Sanitized Copy Approved for Release 2013/04/16: CIA-RDP81-01043R001900100003-3
Declassified in Part - Sanitized Copy Approved for Release 2013/04/16: CIA-RDP81-01043R001900100003-3
?
Table h (corttd)
2. Tr- to design with the ob.4ect to obtain symmetrical forms in the plane of sep-
aratior and s:rnetrical slopes for the projecting walls (simplifies the making
of the dies, eases the stamping operation and lowers the amount of rejects).
a) 3hapc 2 is desirable; the hollowness
is the same in the upper and lower
dies; it can be turned ovpr during
t:!e operatic): to remove the scale and
for better formation of t-e shape.
All this is not obtainable with
shape 1, which is undesirable.
b) The walls in shape 1 have different
slopcs.in relation to the plane of
separation. During the stamping it
will cause the appearance of stresses
tending to displace one die from
another. This defect is absent in
shape 2.
3. Try to design the configuration with the object of avoiding additional opera-
tions such as twisting and bending. The design should strive to reduce the
number of stage operations (ease of operation).
a) Crankshaft (1) having eight throws
cannot be so stamped, as to have its
throws at an angle of 900. This is
due to the poor configuration of the
webs which prevents the setup of the
separation. The throws are stamped '
in one plane and, by a special
machine, are twisted thereafter by
an additional operation. The eight-
throw shaft (2), with a similar
elliptical form of the webs, makes
the separation of the dies possible
and allows the stamping (in one oper-
ation) of the shaft with the webs at
an angle of 900 without twisting.
188
- STAT
Declassified in Part - Sanitized Copy Approved for Release 2013/04/16: CIA-RDP81-01043R001900100003-3
Declassified in Part - Sanitized Copy Approved for Release 2013/04/16: CIA-RDP81-01043R001900100003-3
' Table A (eortid)
b The piece shown at left end
is stamped with its form
developed, the bending is
doneial'ter. The. piece
a)
sho...rn at t;e riFht end is c)
stamped also ir developed a ga 150
' .--151? ?
_ _
.
.
Corm., Tht i this c.Lse,
_
_
'cording passes are rot b)
I
.
-
1
--
.
required, thereeore, the 40=0
stamping has a simple cor -
fiFuratior. In the first
case, the excess of metal
is 87'. of the weirlt of a) After
the Stampinr.; in the follow;
second case it is 335.
stamping;
c)
b) Lines
After bending
b)0 4
jJ
..
of bending to
. .
/. When the minimm thickness o.' the walls after
the drillingdrilling of holes is to be frlaranteed, tie
lugs (teats) should be made oval in shape and
in the direction of a possible displacement.
.
75
.
___
5. In each separate case, determine the advantage of fabricatinr the product from
two or more parts to be welded together arter the stamping, and vice versa,
the advantage of first welding or fastening by arl:i other means, several pieces
to be stamped as one piece.
a) Piece (1), as a single piece, is too .
complicated to be stamped, requirirg
excess material equal to :1, of the
weight of the stampinr. The simoI
piece (?).whel welded; is simpler to
be stamped in parts (there are no
branching) with an excess of material '
reduced to /L0'-% l'arkinrs o7 the
holes.is possible. ,
M
1
'
I.
,
ArC
w
eldmq fl
I
"i
I
? --Q - --
- 19112110 .

,---- ?120
' .
b) The stampirr of a ore-piece connecting
rod is rot ills-r; it is hard to obtain
a clean cut of the burrs in the ,fork .
of the rod; also ar oval sliape. for
the stem; and th3 excess material is
93. These defects can be eliminated .
by welding witl- a reduction or excess
material to W. .
.
,
170? ---1
__Is-
.
----,4
_
.
.
189
STAT
Declassified in Part - Sanitized Copy Approved for Release 2013/04/16: CIA-RDP81-01043R001900100003-3
Declassified in Part - Sanitized Copy Approved for Release 2013/04/16: CIA-RDP81-01043R001900100003-3
Table 4 (cont!d)
c) Two levers (1) and (2), to be fastened
to a third piece, can be designed
as one piece (3). Although the
stamping will be more complicated,
this method, by economizing about 1,kg
of metal, is more advantageous
d) The stamping of the lever as one
piece io more economical than stamp-
ing two parts to be welded together
after.
6. Always look for the possibility and advantages of cutting by coining (cali-
brating) as a substitute for the mechanical treatment of the surfaces after
the stamping is finished.
tn.
%.213
EE
?
a) Reduction of Working
Time by Coining:
25.8 min
b) Reduction of Working
Time by Coining:
19.4 min
c) Reduction of Working
Time by Coining:
10.0 min
190
STAT
Declassified in Part - Sanitized Copy Approved for Release 2013/04/16: CIA-RDP81-01043R001900100003-3
Declassified in Part - Sanitized Copy Approved for Release 2013/04/16: CIA-RDP81-01043R001900100003-3
IN*
?
Table 5
Instructions for Designing Products to be Stamped in a Horizontal Forging
Machine (Bib1.4, 5, 8, 1)
1. The following stamping slopes must be used
on each side for cylindrical portions which
the upper die, if their length is more
as a minimum: a) Yot less than 0.50
are to be shaped in the recess of
than 0.5 of their diameter.
__
,
,
?
'
b) Not less than
shoulaers which
in the deep recesses
0.5-1.5?
are
__
on a side for c) For walls of
to be formed punched by
of the matrix the limit is
, oc.ar4J4
; 171
1
deep impressions
the upper die (plunger)
0.5 - 30
L
I1
.-4;,/,',,
17
_ .
-7-a'zL
a=ar,-1.5*
:La
.
1
,
2. Transitions should be made with radii
of not less than 1.5 - 2.0 mm
of
)
- , L.
?? ?1 --2
? ?
1
/
N',..
,
.
3. When forming a piece having the shape of -a rod with a flange
down) on the end or in the middle, the volume of the flange
exceed the rod volume V2 of a riven diameter by a length
?
1 'f:
.
(by pressing
Vi should not
1 = t104- 12)d.
? =- 4. , r r ' -
r- -
r r
1.13
1
kro-oe, loo-lvd
1 . .
a) Correct b) Wrong
.
1 q
191
1????11,
..-?????
STAT
Declassified in Part - Sanitized Copy Approved for Release 2013/04/16: CIA-RDP81-01043R001900100003-3
Declassified in Part - Sanitized Copy Approved for Release 2013/04/16: CIA-RDP81-01043R001900100003-3
?-?
Table 5 (conttd)
4. Avoid narrowing of the longitudinal cross section of the forging which con?
stricts-the fluidity of the metal when meeting the plunger.
-1
a) Correct
b) Wrong
5. Avoid conical shapes for the removable parts and tail ends.
a) Correct
b) Wrong
6. Wall thickness of pieces with deep openings (open or aosed) should not be
less than 0.15 times the external diameter of the piece.
a) Correct
-z!!
b) Wrong
Thermal Conditions for Forging and Hot Stamping .
Forging and hot stamping should be effected at temperatures which ,will insure
the recrystallization of the 'metal during the process. A complete recrystallization
usually takes place at temperatures above (0.65-0.75)Tp1, where Tpl is the absolute
temperature at beginning of the melting (Bib1.10). Forging and stamping accompanied
192
STAT
Declassified in Part - Sanitized Copy Approved for Release 2013/04/16: CIA-RDP81-01043R001900100003-3
Declassified in Part - Sanitized Copy Approved for Release 2013/04/16: CIA-RDP81-01043R001900100003-3
?
only by a partial recrystallization, in most cases, will bring a nonuniform structure,
which works against the process of deformation.
Complete recrystallization depends not only upon the temperature, but also upon
the rate of deformatior. IncreasirE the rate of deformation hampers the recrystal-
lization.
The maxi= permissible warming temperature and the optimur temperature at the
end of forrinE are set for different allcr-s differently.
Heating to a higher temperature than necessary will he responsible for a coarse-
grain structure or the forging. Also, heating to a temperature near the melting
point brings an "overburn" which is responsible for the complete loss of plasticity
and the product becomes an irrecoverable loss.
Continuing the forging at temperatures below the optimum for the end stage of
forging will bring hardening of soft metal and cracks in a hard metal. Ending the
forging at temperatures above the optimum will make the grains grow.
Temperature intervals for forging and stamping arc shown in Table F.
The process of heating the raw piece is realized in forges, furnaces and by an
electric current.
The heating should provide; a) a temperature required by the raw piece at a
uniform rate of warming-up, along the length and the cross section of the piece;
b) the metal shorld remain as a single solid piece; c) minimum decarbonization of
surface layer and minimum loss of metal in scale formation.
The rate of Warming-up the raw piece to a given temperature depends upon the
furnace temperature, method oC placing the raw piece at the bottom of the furnace
(singly, in close contact, on a shelf, etc.), the size and configuration of the
X
piece and upon the ph?sical properties of the metal (heat conductivity a =
cy
where X is the heat conductivity, c is the heat capacity and y is the specific
weight.
. The basic factor, other conditions being equal, controlling the rate of warming-
193
^ .11111.
STAT
Declassified in Part - Sanitized Copy Approved for Release 2013/04/16 : CIA-RDP81-01043R001900100003-3
Declassified in Part - Sanitized Copy Approved for Release 2013/04/16: CIA-RDP81-01043R001900100003-3
?
up the metal in the furnace is the temperature of the effective space of the furnace.
However, the higher the difference between the temperatures of the effective space
Table 6.
Temperature Intervals for Forging and Hot Stamping (Bib1.2, 15)
Alloy by Chemical
Analysis in %, or
by Trade Mark
d
Temperature in 0?C
Beginning of
Melting
End of
Melting
? Carbon Steel
.
'
Carbon up to 0.3
lf OP
0.3-0.5
ft 11
0.5-0.9
81 /I
0.9-1.5
1200-1150
1150-1100
1100-1050
1050-1000
?
-
800-850
800-850
800-850
800-850
Alloyed steel
-
Low alloyed steel
Medium alloyed steel
High alloy content
1100
1100-1150
1150
825-850
850-875
875-900
Aluminum alloys
Ill
AK2, A4(4, AK5, AK6
i"?470
. .
,
470
490
350
380
400
.
Magnesium alloys
MA1, MA2
MOS
MM
430
400
370
350
300
300
Copper alloys
BT. AZI1 0-4; Dr. A211?Mts 16-3-1.5;
Br. AZIA 10-4-4
LS 59750
?
850
. .
700
600
.
.
' Nickel alloys
. .
Monel
Nickel
1180
1250
1000 (870?) .
1000 (870*)
?
* Forging by means of light impacts
of the furnace .and the surface of the raw piece, the higher will be the temperature
gradient across the raw piece. This gradient increases with the decrease in the
conductivity of the metal and with the increase of the cross?sectional area of the
raw piece.
194
STAT
Declassified in Part - Sanitized Copy Approved for Release 2013/04/16: CIA-RDP81-01043R001900100003-3
Declassified in Part - Sanitized Copy Approved for Release 2013/04/16: CIA-RDP81-01043R001900100003-3
'
?
?
?
?
The temperature gradiept is the source of thermal stresses. These stresses,
especiall- i- the prescrce or residual stresses ir a cold raw piece, in the first
period of heatitg (i.e., before passinr through i:e interval of structural conver-
sion Aci -
Ac3) can bring the disruption of the solid state of the metal and the
appearance of macro and micro cracks.
In small forgings made of structural steel with a diameter of 100 to 150 mm and
heated rapidly, the above-mentioned effects are not observed. Such forgings may be
placed in a furnace with an effective space temperature higher by 100 - 150?C than
the required end temperature.
Cold alloyed steel pieces of low heat conductivity, also large cold pieces and
castings of all trade marks, for such metals, onl:,r a permissible rate of heating
should be maintained. The furnace temperature, at the time of placing the raw pieces
in the furnace, should be considerably lower than the temperature during the forging:
for carbon-steel castinrs weighing 1 - 2 t 9000C, for steels with high alloy con-
tent 500 - 600?C, for large castings of all trade marks, weighing , 60 m and
over , 200?C.
7arther heating is accomplished by gradual raisinr the furnace temperature or
b- shiftirr the raw pieces to zones of higher temperatures (methodical furnaces); the
first period of heating should amount to 60-705 of the entire duration of the heating.
The seCord heating period, i.e., from the critical to the temperature of the
forging process, should be carried out with an high rate, to avoid intensive growth
of the grains, decarbonization of the surface ard formatioh of scale.
The duration of the heating of small steel pieces is Shown in Table 7. The
duration of the heating of castings, and of pieces the dimensions of which are not
shown in the table, can be found by the equation worked out by Dobroktov:
t? = kD Vi
'where t is the full time duration of the heating per hour; D is the diameter Of the
195
.411.
STAT
Declassified in Part - Sanitized Copy Approved for Release 2013/04/16: CIA-RDP81-01043R001900100003-3
Declassified in Part - Sanitized Cop Approved for Release 2013/04/16: CIA-RDP81-01043R001900100003-3
piece in m; k is a coefficient equal to 12.5 for carbon steel and for steel with
low alloy content, and is equal to-- 25 for steel of high alloy content (Bib1.18).
Table 7
The Rate of Heating of Structural Carbon Steel from 15 to 12000C (in min)
(The Effective Space Temperature of the Furnace is 13000C)
Diameter d, or Side of Square
in mm
Shape of the Haw Piece
Round
Square
Methods of Placing of Raw Pieces in the Furnace
At a Distance Equal
to d
[_ ---,
At a Distance Equal
to 0.5 d
In Close Contact
Singly
At a Distance Equal
to d
At a Distance Equal
to 0.5 d
In Close *Contact
?,
.-4
40
Z
.r4
CI)
10
2.0
2.0
3.0
4.0
2.5
3.5
4.5
8.0
20
3.0
3.5
5.0
7.0
4.5
6.0
8.0
13.0
30
5.0
5.5
7.0
10.0
6.0
8.5
11.0
19.0
40
6.5
8.0
9.5
13.0
8.0
11.0
14.0
25.0
50
8.0
9.5
12.0
16.0
10.5
11.5
17.5
32.0
60
9.5
11.5
14.0
19.5
12.5
17.5
21.0
38.0
70
11.0
13.5
16.5
22.5
14.5
20.5
25.0
44.0
80
13.0
15.5
19.5
26.0
17.0
23.5
28.5
52.0
(
90
15.0
18.0
23.5
31.0
. 1..5
27.0
33.5 ,
62.0
100
18.0
21.5
27.0
36.0
23.0
32.5
40.0
72.0
-
Remarks: 1. The time-rate of heating short pieces, as compared with values
shown in the Table is: 0.98 when the length is 1 < 2d; 0.92
.
with 1 < 1.5d; and 0.71 when 1 = d.
2. For instrument carbon steel with a medium alloy content, the
time-rate of heating is increased by 25 - 50%. For structural
and instrument steels with a high alloy content, the time-rate
? of heating is increased from 50 to 100% .
When hot ingots are placed in the furnace, the Values of k as shown above, may be
cut in two.
Heating by electricity (induction method and contact) offers substantial ad-
196
-
Declassified in Part - Sanitized Copy Approved for Release 2013/04/16: CIA-RDP81-01043R001900100003-3
Declassified in Part - Sanitized Copy Approved for Release 2013/04/16: CIA-RDP81-01043R001900100003-3
?
?
vanta7es over heatinp in a furnace. These advantages are: a) hir:h rate of heating;
b) easy control of the temperature; c) absence of scaling; d) possibility for arto-
matization which allows the adjustment of the time for placing and re-oval of the
pieces into and from t.e furnace; e) possibility of raising the initial forging tem-
perature without of overheating; f) makes Cor better working conditions; g) ever
present readiness to start operations.
FOr heatin- b-J- the irduction method, currents of ury frequency may be used
(usually in industry, or high frequency). The cost of electricity can be reduced
to a minimum by coordinating the frequency with the diameter of the piece to be
heated.
The following frequencies are recommended: 8000 cycles for pieces having a
diameter of 20-1L5 mn; 2500 cycles for pieces wit. 30-80 nm in diameter; 1000 cycles
for pieces with 50-1h0 mm in diameter; 50 cycles when the diameter of the piece
is 130 mm and longer.
For heating of a large number of pieces, or in mass-production, it is best to
use a metallic type induction heater and to heat several pieces in one time. The
pieces to be laid out one after another along the axis of the induction coil. The
number of pieces n to be placed at one time in the heater is:
?
_ T
where T is the heating time in minutes and t is the desirable rate of removing
heatedpiecesfromt'refurnace.Ifp.is the diameter of the inductor and Dz is
the diameter of the piece, then, with the increafie in the ratio L1 the heater
efficiency falls of sl-urply. It is therefore desirable to maintain the following
ratios. For pieces with a diameter up to 50 mm the ratio should be Di < 1.6 - 1.8
Dz
D.
and ?2- < 1.2 - 1.h for piedes vThose diameter is over 50 mm (Bib1.11)'. Information
Dz -
oh duration of heating and the necessary power is given in Table 8. .
heatinr by the contact method (due to the heat of ohmic resistance
197
1
STAT
Declassified in Part - Sanitized Copy Approved for Release 2013/04/16: CIA-RDP81-01043R001900100003-3
StAT
Declassified in Part - Sanitized Copy Approved for Release 2013/04/16: CIA-RDP81-01043R001900100003-3
?
Table 8
Time Necessary for Induction Heater to Heat Raw Pieces to
Final Forging Temperature
Diameter of the Pieces
in mm
[ Assumed Consumption of
Electrical energy in
kw per 1 kg
Technologically Mini-
mum Permissible Time
of Induction Heating,
in fin
Length of the Pieces in mm .
I
80
100
125
160
200
250
320
I 400
500
_
1
Heating Time in min per 1 Piece
Frequency 8000 cycles, Power of Installation 100 kw
-
20
0.5
0.03
0.07
0.08
0.1
0.13
0.16
0.2
-
-
-
30
0.49
0.1
0.14
0.18
0.22
0.29
0.36
0.45
0.58
-
-
40
0.48
0.2
0.25
0.31
0.39
0.45
0.62
0.78
1
1.25
-
SO
0.46
0.5
-
0.47
0.58
0.75
0.94
1.17
1.5
1.87
2.34
- -
-
Frequency 1000 - 2500 cycles, Power of Installation 100 kw
i
60
0.49
1
-
-
-
1.04
1.3
1.47
2.09
2.58
3.24
80
0.47
2
-
-
-
1.78
2.25
2.8
3.55
4.5
5.6
100
0.45
3
-
-
2.65
3.35
4.15
5.3
6.64
8.3
120
0.43
4
-
-
-
3.65
4.6
5.7
, 7.3
9.2
-
140
0.4
5.8
-
-
-
-
5.8
7.3
9.3
-
-
Usual Industrial Frequency, Power of Installation 200 kw
160
0.48
6.2
-
-
-
-
-
-
.7.3
9.1
11.4
180
, 0.46
6.6
-
-
-
-
-
6.9
8.8
11
13.8
200
0.44
7
-
-
-
-
6.5
8.2
10.3
13
-
250
0.41
9
_
_
-
r
. -
9.5
11.8
15.2
-
-
300
0.38
11
-
-
-
10.1
12.6
15.8
-
-
-
_
Remarks: 1. The values shown in the Table should be multiplied by 1.15 when heating alloyed .
steels; by 1.2 - 1.3 for nonmagnetic steels; and by 1.25 for pieces with a
square shape.
2. If the power of the installation is increased or decreased, the time shown
in the Table is also increased or decreased proportionally
- .
198
-.111?11111b
Declassified in Part - Sanitized Copy Approved for Release 2013/04/16: CIA-RDP81-01043R001900100003-3
Declassified in Part - Sanitized Copy Approved for Release 2013/04/16: CIA-RDP81-01043R001900100003-3
?
?
?
of the Corriur beini a part of the elecLrical circuit) is vex.; convenient for lour
piece ADDSC profiles ,,re small. Installatio's of this uaLpre arc much simpler and
Table 9
Secondary Voltage and Power Required for reatinr a Piece 100 mm
Lonr by the Electric Contact Method (libl.11)
Diameter of the
piece in nun
:!eating time t, in min
0.15
0.3
0.6
1.2
2.4
Secondary voltare v, in Volts
2.36
1.67
1.18
0.8h
0.59
Power P in kw
20
19.3
9.7
4.8
2.4
1.2
30
58
29
14.5
7.25
3.6
40
,
97
1$.5
2h
12.1
4.1
50
145
73
36.2
18.1
9.1
')0
106
53.2
0A.A
13.3
The recpired secondarY voltare v2 and the power P for heatin-
pieces with a diameter Dz ard lenrth E witl- a heatirr duration
chosen as t, will be: v2 = vk; P = pK
The length of
the piece LI
in mm.
,
Diameter of the piece Dz in mm
20 ?
30
40
50
60
Correctior factor K
2.h2
'
2.70
2.9
-
-
200
300
3-5.
3.84
. 4.1 ?
4.55 S
_ ,
LOO
4.68
4.93
5.36
5.65
? -
500
5.85
6.1
6.5
_6.85
7.25, .
600
7
7.15
,7.f,
8.1
8.35
,
-
the capital irvestment is less than for the inductior type heaters. There should be
s 199
STAT
Declassified in Part - Sanitized Copy Approved for Release 2013/04/16: CIA-RDP81-01043R001900100003-3
Declassified in Part - Sanitized Copy Approved for Release 2013/04/16: CIA-RDP81-01043R001900100003-3
?
?
Cl O1[ pressure between the clamps aid the surrace of the forging. The pressures
shovld be as follows: 1000 kg/cm2 for pieces with a diameter of 20-30 mm; 3000 kg/cm2
for diameters of 30-50 mm; 5000 kg/cm2 for diameters of 50-70 mm. Information on
heating time, power and secondary voltage and their relation to the size of the
piece are shown in Table 9.
After forging, the cooling conditions are just as important as the heating
conditions. Too rapid dooling creates thermal stresses resulting in internal and
exterraI cracks. The smaller the heat conductivity of the steel and the larger is
the size of the raw piece, the slower is to be the rate of cooling.
Technological Processes and Equipment
The basic technological processes and the equipment used in forging are Elven
in Table 10. Prof. A.P.Oavrilenko, was the first to give a detailed report on prob-
Fig.21
Fig.22
lems connected with forging under pres-
sure. There are three basic groups of
processing methods: free forging, stamping
and the finishing group.
Free Forging. General information.
Free forging is effected by hydraulic
presses, by steam, pneumatic and spring-
operated hammers.
Heavy and very heavy forgings to be
made from cast ingots are being forged
exclusively by hydraulic presses with
power over 800 t.
Vedium-weight forgings, originally from rolled material (stripped ingots,
forge-shop irgots, etc.) are made by steam hammers with falling parts weighing 1-3 m,
and are also made by hydraulic presses with a power of 400-800 m, and seldom by
STAT
200
neclassified in Part - Sanitized Copy Approved for Release 2013/04/16: CIA-RDP81-01043R001900100003-3
Declassified in Part - Sanitized Copy Approved for Release 2013/04/16: CIA-RDP81-01043R001900100003-3
?
?
Table 10
Basic Technological Processes and Equipment. used in Forging and
Stamping
a.)
b)
1)
C)
13)
e) ?
i)
K)
m)
II
g)
11)
F))
o)
`1)
ae)
2
3
1
2
3
?
?
?
10
2
1
2
3
?
?
bb)
4
4
11
9
14
c c)
12
12
?
ota)
5
13
15
e e)
7
7
8
8
?
if)
?
2-5
99)
6
?
16
I'
20
11
kk)
U):
17
17
nn)
;8
00)
?
/9
?
19
19
21
P! )
d)
q)
s) t) u)
23
_ I _
22
24
2.5
? 28
29
30
26
.27
x) '
5
a
9
200a
10
11
Declassified in Part - Sanitized Copy Approved for Release 2013/04/16: CIA-RDP81-01043R001900100003-3
Declassified in Part - Sanitized Copy Approved for Release 2013/04/16: CIA-RDP81-01043R001900100003-3
?
/44
/1
IJ
/4
111
11
f
2J
MIN
gm,
/7
15
27
74
25
.16
251
Jo
a) Type of processes; b) Hammers; c) Presses; d) Forging machines; e) Steam air; f) Crank
type; g) Forging; h) Stamping; i) Pneumatic; j) Friction; k) Spring lever; 1) Hydraulic;
m) Screw friction; n) Hot stamping; o) Cutting; p) Ciankthrow; q) Horizontal forging;
r) Vertical forging; s) Rotary forging; 0 horizontal bending machines; u) Forging rolls;
v) SMith,stamping automatic; w) Hot milling cutters; x) Abrasive machines;, y) Forging,in
particular; z) With shaped strikers; aa) With backing open dies; bb) Stamping in tightly
held open dies; cc) Stamping by plungers in closed dies with one-piece matrixlin partic-
ular; dd) By piercing; ee) By upsetting; ff) Stamping by plungers in movable matrixes;
gg) Stamping by bending; hh) Drawing through a ring; ii) Fluting; jj) Cutting off burrs;
kk) Cleaning away burrs; 11) Calibrating coining; mm) Voluminal; nn) Snrface; oo) Trueing;
pp) Remarks: In Table 10, the numerals correspond with the'numbers of the sketches below
and indicate how wide is the application of the machine for a given process. The sign (-)
indicates limited or absence of application
200 b
STAT
Declassified in Part - Sanitized Copy Approved for Release 2013/04/16: CIA-RDP81-01043R001900100003-3
Declassified in Part - Sanitized Copy Approved for Release 2013/04/16: CIA-RDP81-01043R001900100003-3
?
?
ple'malic lammers.
ai forrirrs from rolled material (squire, round or strip) -tre made, in most
cases, pleinatic hamrers ard occasionall'r, b., steam ard compressed-air hammers
with falli'r parts weirilirr less than 1 ton. For very simple and ver:- small forpinrs
humper-sprinr operated hammers are used sometimes.
Two t:Tes of hydraulic presses are used:(a)Cour-column frame type (Fir.21)
with 1 to h c:ainders, deperdinr upor the tonnare ard desirn of the press, (b)open
front type shown in Fir.22. Specifications of a Cour-column press are riven in
Table U.
Table 11 Table 12
Specifications of Four-Column Hydraulic Guide for Selecting Hydraulic For,7ing
Forrinr Presses Presses for Ingots of Various Weights
(Taken from COST 72f'/1.-54) (Bibl.115)
a)
b) c)
d)
500
810
1600
1180
800
1000
20110
I 1'0
I ni
12.50
2100
11190
211o0
16 hi
3200
2160
32 0
2.0o
4 00
3010
9. iu0
2510
5.1;0
'1750
e)
a)
C)
b)
C)
d)
51
(1)
111
250
440
600
Mi)
Imo
1200
151/0
I
2
3,5
.
,,
8
3
5,5
8
II
17
ill,
,
I
11
2 000
3 Tro
6 000
10 40o
?
34
311
811
160
28
55
120
240
a) Rated power in m; b) !'aximum length a) Power of press in m; b) Weirht of
of stroke in mm; c) Ea:Kir= distance the inrot in m; c) Averape; d) nax-
betweer the stand ard movable cross- mum
piece in mm; d) Inner distance between
colunrs in inn; e) Appro:dmate wei-ht
in in
201
STAT
Declassified in Part - Sanitized Copy Approved for Release 2013/04/16: CIA-RDP81-01043R001900100003-3
Declassified in Part - Sanitized Copy Approved for Release 2013/04/16 : CIA-RDP81-01043R001900100003-3
^
?
As to the type of the drive used, there are: purely hydraulic presses deriving
the power from a pump and a hydraulic accumulator, and steam-hydraulic presses de-
riving the power from a steam-hydraulic manifold. In this type of press, compressed
air may be used instead of steam. The tonnage required for ingots of different
weights is shown in Table 12. The relationship between the capacity of hydraulic
forging presses and the complexity of the configuration is shown in Table 13, where
the capacity is shown for forging without the use of a manipulator; the use of an
manipulator increases the capacity 1.5 - 2.0 times (the less complex is the configu-
ration - the larger is the capacity).
Table 13
Complexity of the Configuration of a Forging and its Effect on the Capacity of
Eydraulic Forging Presses (Bib1.45) (When a 2:anipulator is not Used)
a)
bi
GOO 800
j 1000 1200 1500 2000
3000
270
320
370
430 480
570
680
II
510
GOO
700
790 890
114/0
1150
Ill
650
850
1040
1250
1410
1750
2100
I 930
1150 1400 1640
1920 2250
2630
1550
1830 2100 24o0
2710 125U
ii Ill
111
f
a) The complexity group; b) Capacity per hour, in kg, with the
power of the press measured in m
Forge Hammers. Two types of air and steam operated forge hammers are commonly
used; these are: open-front single-side frame type (FiE.23) and two-sided frame
-type which are divided into arch type-(Fig424)- and-br4dce-4.ype -(Fig.954v
202
STAT.
Declassified in Part - Sanitized Copy Approved for Release 2013/04/16: CIA-RDP81-01043R001900100003-3
Declassified in Part - Sanitized Copy Approved for Release 2013/04/16: CIA-RDP81-01043R001900100003-3
Y.?
1
1754:.23 - 0per-7ront
Air ard Ste.ari Oper-
ated For-e 7.anner
T..121,10 lA
- Arel.-T:Te
Two-Sided Trame Air
ard Ste;:..r. Operated
Forge "arraer
1'ig.25 - Tiriclge-'11:Te., Two-Sided
.7rane, Air ard Steam Operated
Forge '.1arlr'.er
Table 15
Specificatio-s of ::rch-71:-.pe Air and Speciricatiors of Prennatic Torre
Steam Operated 7orre -nrers ?arturers (Take] from COST 712-52)
from (-70Tr' 1L73040)
a)
b)
c)
d)
woo
1000
1800
410X2.30'
1500
1150
21(X)
470X260
2000
1260
2.300
520x290
3000
1450
?
27(X)
? 590X330
4000
1600
3000
650X370
5000
1700
32/0
710X400
'
a) Woir'A
of fallirr
a)
b)
C)
.
d
e)
75
210
300
145X65
2 656
150
190
350
200X85
4 0 *0
250
150
420
225X93
5 756
401
130
520
265X100
9 00(1
560
115
620
30/ x110
12 000
750
105
750
345)010
17 900
1000
800
390X150
parts ir b) Lenrth a) Weight of fallinr part in kr; b) Nun-
of stroke of the ram in nm; c) Cle,Irance ber of strokes per min; c) Length of
1.)etweer, sides in nn; d) Size of striker "f17rirp-out" in mill; (1) Size of striker
in nn
203
ir mr; 0) Weight of hammer.without its
anvil-block in kr-
STAT?
Declassified in Part - Sanitized Copy Approved for Release 2013/04/16: CIA-RDP81-01043R001900100003-3
STAT
Declassified in Part - Sanitized Copy Approved for Release 2013/04/16: CIA-RDP81-01043R001900100003-3
?
?
Pneumatic forge hammers (Fig.26) are made with a single open front, without
guides, and with the piston, rod and ram as one piece.
Fir.26 - Pneumatic Forge Hammer
Fig. 27 - Bumper-Spring Operated Hammer
specifications for air and steam operated forge hammers are given in Table 14,
and for pneumatic forge hammers in Table 15.
7xlmers operated by bumper springs are made in small sizes and their use is
United. A hammer of this type, with the weight of the falling part equal to 30 kg,
is s'-,own in Fig.27.
Table 16 shows the relationship between the hammer capacity and the complexity
of the forging configuration. The required weights of the falling parts of the
forge hammer in relation to the ingot weights may be determined by using Table 17.
Nanipulators. In free forging by hydraulic presses, the use of a manipulator
is necessary. Its use increases the capacity by more than 1.5 times by the mechani-
zation of the shifting movements of the forging. The lifting capacity of a manipu-
lator, depending upon the power of the press is:(Bibl./.5):
Power of the Press
in m
Lifting power of manipulator
._ in m
600
800
1000-1200
2 - 3
3 - 5
5 - 10
Declassified in Part - Sanitized Copy Approved for Release 2013/04/16: CIA-RDP81-01043R001900100003-3
Declassified in Part - Sanitized Copy Approved for Release 2013/04/16: CIA-RDP81-01043R001900100003-3
?
Power of the Press
in m
Lifting Power of the manipulator
ir m .
1500
10
- 15
2000
15
- 20
2500-3000
30
- 50
5000-4000
75
- 100
Table 16
(uide to the Relationship between Capacities of Forge Hammers and Complexity
of ConfiFuration in Forrinrs Nibl.45)
a)
b)
0.1
0,15
0.2
0.3
0.4
0.5
0.75
1
2
:i
I 5
3.5
4.5
13
17
26
37
83
111
151
II
6
7.5
9
15
25
38
6.5
97
160
210
2:0
III
7
9
12
19
30
45 PO
115
220
295
3FM
IV
9
II
14
26
40
60 105
1.II
235
310
4N
V
12
15
18
32
52
75 133
165
265
350 5(0
VI
11
19 25
42
68
98
155
321)
430 580
VII
20
25
32
50
75
105
170
225
370
5(X) 65)
VIII
28
32
40
60
90
120
210
515
711 921)
IX
83
ss
113
155
200 250
370
41;5
915 1210 1500
6-s -1
c___ EZ ..
E;=)"'a 451:9 adiezi
0- ) 4w/ilia-alp. .;;;;, 9
&14=A 1111
,3_ a0=-----4101 0=m2 1:-----.1
(*E-71-=-1 C? E 1 V'l----=::S
I II 1.11 /7 , V
eisionnum
a) CoMplexitr group; b) Capacit7 per hour, ir kg, with weight of
falling part in m
Even with the use of , manipulator, the use of a bridge crane is also Lecess?lry.
The over-all weig'.t of material ir free forgirg is determined from the follow.-
equation:
.4a
STAT
Declassified in Part - Sanitized Copy Approved for Release 2013/04/16: CIA-RDP81-01043R001900100003-3
Declassified in Part - Sanitized Copy Approved for Release 2013/04/16: CIA-RDP81-01043R001900100003-3
where ?
Cris
G. =G +G 4-G +0
is Pk pr ug ob
is the overall weight of material; Gpk.is the weight of the forging; Gpr is
the weight lost by the added part of the
Table 17
Guide for Selecting Proper Weight of Falling
Parts of Forge Hammers for Forgings of
Various %eights (Bib1.45)
Weight of Falling
Parts in m
Weight of Forging in kg
Maximum Cross-Sectional
Area of Raw Forging (Side
of Square) in mm
Shaped Forgings
Average Weight
Maximum Weight
Maximum Weight for
Smooth Rolls
0.1
0.5
2
10
50
0.15
1.5
4
15
60
0.2
2
6
25
70
0.3
3
10
45
85
0.4
6
18
60
200
0.5
8
25
100
115
0.75
12
40
140
135
1.0
20
70
250
160
2.0
60
180
500
225
3.0
100
320 ?
750
275
5.0
200
700
1500
350
.ingot; Gdn is the loss by the ingot; Gug
is the loss by burning; Gob is the loss*
by chipping.
The loss in weight from the added
surplus part of ingots, made from struc-
tural carbon steel and cast from above,
is usually 15-25% of the ingot weight.
For structural alloy steel; 25 - 35%.
Ingots cast without the use of a warming
ekepiece will lose up to 35-40%. For
instrument alloy steel, the surplus mater-
ial may go up to 50%.
The lost weight by the 'ingot Gan is
assumed to be at 4-7% for carbon steels
and 7-10% for alloyed steels. In per-
centage of the over-all material, the
loss by burning can go up to 2% of the
material being heated for each heat, and
to 1-i% for each preheat. The loss by
chipping depends upon the complexity of
the forging and also upon. the technological process used. For forgings having the
same configuration, the smaller pieces will have a greater loss.
The percentage of total loss due to burning and chipping for different forgings,
forged by hammers from measured stock is as follows: STAT'
206
_
YID .0111P
Declassified in Part - Sanitized Copy Approved for Release 2013/04/16: CIA-RDP81-01043R001900100003-3
Declassified in Part - Sanitized Copy Approved for Release 2013/04/16: CIA-RDP81-01043R001900100003-3
?
Forrinrs by rroup
Loss in 5
of Weight of
Forrinr.
7,nd flanges - round, ov111 flat, square, strips, cubic,
blocked
1.5-2.5
Oper flarges, collars, ruts
2*
_]nd :ears
-10
74xparder rings, bushings, sI ells
2.5*
Welded rirgb, bus'siurs, shells, couplinrs
3--5
Smooth shafts, rollers, square, straight, _Lnd hexa-oral
blocks
5-7
Shafts and rollers with projectiors or flanges, ke7s,
s=oes, trxrerses
7-10
Shafts, rollers with recesses on two sides, or with
shoLlders, spirdles, rods, ,rokes
10-12
Levers for tigl-teninr nuts, forginrs of the connecting
rod type, levers, compourded connecting rods
15-18
Cranks
18-25
Crankshafts, curved and two-shouldered levers
25-30
* Does not include losses due to waste of pnnched-out material. These loses have to
be calculated and added additiorally. 'Then a backing ring is used, the volume Vv
of the wasted
punched-out mterial is:
nd2
Vs ^- (0.70 4- 0.75) 4 h = (0.55 0:60) d2h
When punching without the use of a backing ring, the volume or the punched-out
miterial is:
Vs (0.20 0.25)
ad2
h = (0.15 0.20) d2h
4
When the punching is done with a hollow punch (when forging in a press), the volUme
ltd2
V :t (1.1 4- 1.15) s
s h
4
where d is the diameter of the punch; h is the height of the stock; ds is the dia-
meter of the hole.
207
STAT
Declassified in Part - Sanitized Copy Approved for Release 2013/04/16: CIA-RDP81-01043R001900100003-3
I I.
Declassified in Part - Sanitized Copy Approved for Release 2013/04/16: CIA-RDP81-01043R001900100003-3
e ?
?
?
The approxinate weight after deducting losses and waste of the cast-iron ingot
suitable for forging is shown below:
.vorging by Croup
Remainder in % of
Weight of Ingot
Straight shafts and rods
60-70
Shafts with long wristpins '
58-64
Shafts with short wristpins and shafts with flanges
on both ends
54-60
Single throw crankshafts
50-58
niltithrow crankshafts
40-50-
Plates and stri material
50-65
Cubic shapes
52-60
Rings and bandage
55-56
Discs
50-60
Drums, hollow cylinders
60-65
-
Sizes of In.-ots to be Forged (Stock). When the forging is to be done by the
method of upsetting, consideration should be given to the weight of the stock and its
volume (Vis). The sizes are to be so selected that the height his does not exceed
the diameterdis, or the side of the square, by more than 2.5 times (to avoid bends
by. the upsetLing). Nevertheless, the height must be 1.25 times larger than the
diameter (to make the chipping and the outting by shears easy). In other words,
1.25di6 < his < 2.5di5
Withthisrelationshipwehave:.
dis =(0.8 - 1.0) VV. for round stock, and d. =
is is
= (0.75 - 0.90) VVi, for square pieces.
The length or the stock is found by dividing the volume by its crqss-sectional
area, in accordance with the precisely determined diameter, or the side of the
square of the stock, corresponding exactly to the grade of the stock, as specified
by COST.
208
STAT
Declassified in Part - Sanitized Copy Approved for Release 2013/04/16: CIA-RDP81-01043R001900100003-3
Declassified in Part - Sanitized Copy Approved for Release 2013/04/16: CIA-RDP81-01043R001900100003-3
?
The approximate weight after deducting losses and waste of the cast-iron ingot
suitable for forging is shown below:
,
Forging by Croup
Remainder in % of
Weight of Ingot
Straight shafts and rods
60-70
Shafts with long wristpins ,
58-64
Shafts with short wristpins and shafts with flanges
on both ends
54-60
Single throw crankshafts
50-58
:'ultithrow cranksafts
40-50
Plates and stri material
50-65
Cubic shapes
52-60
Rings and bandage
55-56
Discs
50-60
Drums, hollow cylinders
60-65
Sizes of InFots to be 7orred (Stock). When the forging is to be done by the
method of upsetting, consideration should be given to the weight of the stock and its
volume (vis). The sizes are to be so selected that the height his does not exceed
the diameter dis, or the side of the square, by more than 2.5 times (to avoid bends
by the upsetLing). Nevertheless, the height must be 1.25 times larger than the
diameter (to make the chipping and the cutting by shears easy). In other words,
1.25di5 < h. < 2.5d.
is- Is
With this relationship we have: d. -1.0) VV. for round stock and d.
is is is
for square pieces.
3
= (0.75 - 0.90) VT
Is
The length of the stock is found by dividing the volume by its cross-sectional
area, in accordance with the precisely determined diameter, or the side of the
square of the stock, corresponding exactly to the grade of the stock, as specified
by COST.
208
STAT
Declassified in Part - Sanitized Copy Approved for Release 2013/04/16: CIA-RDP81-01043R001900100003-3
STAT
Declassified in Part - Sanitized Copy Approved for Release 2013/04/16: CIA-RDP81-01043R001900100003-3
?
?
Pioi selectin- slock of rr...a !e.i.-11 to be for -ed under Lite :ammer, it is oeces-
sAr:- s.o verif- rte to do it hechricall:- h- upsettin:-, usin,- the equation
"as
0.25 'I
where r is the length of stroke of the hImer. For forrinr of a cast inrot by up-
settinr, the specifications of the inrot should be ir lire with the over-all weirht,
which is to be calculated, as shown above.
lihen forrinr b7 drawing-out: Corrins with round, square, or nearly round or
square shapes of their cross section, should follow the followinr relationship:
1 re
IS MaX
where Fis is the cross-sectional area of the over-all stock- F is the area of the
' max
maximum cross section of the forrinr; 7 is the derree of forrinr (see earlier in
text).
Dasic Operations of the Technolorical 7rocesses in Free Forrinr. These are:
1) Upsetting, 2) drawirr out, 3) purchinr, 4) cuttinr, 5) bendirr, 4)) twistinr and
-) forge weldinr.
Upsettinr. upsettirr, the heirht of the oriFinal stock is reduced at the
expense of the increase ir t'le area of its cross section. Upsettnnr, wher done only
for a portion of the stock is called partial upsettinr. Upsettinr is Used: a) to
obtain forEinrs (or portiors of forrinrs) having rreater cross-sectional areas ard
relative1.7 small 1-ei1hts (flanres, rears, discs) from stock whose cross-sectional
area is smaller; b) as a preliminar- step before punchinr of hollow forrinEs (rings,
drums); c) as a preliminar:,- operation aimed to destroy the dendrite structure of the
castinr ard to improve the qualit7 of the stock having a transveral structure; d) to
increase the deFree of forrinr for the subsequent drawing-out operatior.
The upsetting of a c-Tlirdrical stock from a tailless castirr (pins, shanks, etc)
is done: 1) under harmer, and 2) 1):- a press, when the next operation is punching
209
Declassified in Part - Sanitized Copy Approved for Release 2013/04/16: CIA-RDP81-01043R001900100003-3
Declassified in Part - Sanitized Copy Approved for Release 2013/04/16: CIA-RDP81-01043R001900100003-3
?
(see Fig.28).
The upsetting of a stock having a tail (Fig.29) is done by a press, if drawing
out is to follow. In such cases, backing plates are used, with the lower plate
containing a hole under the tail.
r The upsetting on plates with holes
(backing rings) is peculiar in that res-
pect, that simultaneously with the upset-
ting process, metal will flow in the
holes of the backing rings A and 13
(FiE.30). This method is used to obtain
products of the type of end gears, flanges and discs with lugs or teats. It is also
used in cases where the volume of the product is unusually large in relation to the
diameters of the lugs and, for Some reason
it is undesirable, or impossible to ex-
FiE.28
Fig .29
tend the ends of the product (for example,
if the height of the teats is very small).
Partial upsetting in a ring (Fig.31)
is used to obtain products of the type
of end gears, flanges and disks with
teats, or lugs. It is used in cases, when the diameter of.the lugs (Fig.31a), or
if the end of the stock can be preliminary extended to the same extent (FiE.31b).
Partial upsetting'in the counter-die (the lower die) is used to obtain flanges
and heads on long rOds (FiE.32). The stock may have a diameter equal to the opening
(to the diameter of the rod), or if it is 'possible to have the end of the stock ex.-
tended to the same extent. A cavity, having the shape of the head, can be made in
the upper portion of the lower die (a backing die, Fig.33).
Upsetting by enlarging is used for decreasing the,heiEht and enlarging the
diameter of a product alread:r upset when, due to the high resistance to deformation,
STAT
Fig.30
210
Declassified in Part - Sanitized Copy Approved for Release 2013/04/16: CIA-RDP81-01043R001900100003-3
Declassified in Part - Sanitized Copy Approved for Release 2013/04/16: CIA-RDP81-01043R001900100003-3
?
?
furter itpsettirr II-- direct strikes of the :.arirer (or 1-- pressrre of the press) over
ertire srrface is impossible. Tbe erlarrini is effected means of a roller
?t?
d
0)
Fir-.32
Fir. 33
(?ir.34), or for rorrirrs larpe diameters, (for instarce, turbine disks), di-
recti:? 1)5- means of strikers (Fir.35).
L2_2
a)-
Fir.3h
a) Zrlar:-i:r
roller
a) Strikers; h) Prop
?
b)
The firishinr operitio after 'psettir,, is the rolliix alorp the diameter. It
is "sed to eliminate the harrel-shape Lo inpart a c4indric.,1 form and a smooth
s-rf.ace (Tir.34)a). This operation is male elsier 13- i:sirr an underla7er or squeezers
(Fi-.3(h).
Drawirr-O'A Oporatio:s (7.i.trusior). In drIwi-p-out operations, the lenrth of
Lhe ori!Lal stock ircreases at fte expense or the reduction of its cross-sectional
area (sha:ts, 6ra1;r:.t-bars, connectirp rods, etc). The tools used (Fir.37) are:
a) flat-strikers, b) cUt-out strikers, c) seldom used rounded strikers, d) squeezers,
e) rollers, f) knuckles, r) iiardrils, h) chucks, etc. The drawinp out is effected
STAT
211
Declassified in Part - Sanitized Copy Approved for Release 2013/04/16: CIA-RDP81-01043R001900100003-3
Declassified in Part - Sanitized Copy Approved for Release 2013/04/16 : CIA-RDP81-01043R001900100003-3
?
?
?
b- consecrtive screezirgs (by the squeezers) (Fig.38) while the stock is fed along .
tl'e axis of the drawing-out direction. It is also accomplished by turning the stock
around (edging). The varieties of
? recess tl,is process are:
upp.,
/ for
tool
a) Flattening (widening, enlarg-
lase_
swallow inr), the increase in width of the
lower
1 b)
d)
CS:r-%,01.40
g)
original stock at the expense of its
height. It is used to obtain forgings
or portions of forging having a flat
shape, of the type of flat thin plate.
b) Drawing out on a mandril
(Fig.39), which is increasing the
length of a hollow forging at the
expense of reducing the thickness of
its walls (forging of gun-barrels,
boiler-drums, turbine rotors, etc).
The tools used are: cut-out strikers
(or a cut-out lower atriker and a
flat upper one), and mandrils with-
Fig.37 - Tools used for Drawing-out
slightly conical surfaces.
c) Enlarging on a mandril, which
is the simultaneous increase of the
external and internal diameters of a hollow piece at the expense of the thickness
of its walls (rings, shells, drums). The tools used are: a narrow long upper striker
(preferably to be as long as the forging), a c:rlindrical mandril and supports under
the mandril. The method (Fig.h0) is as follows: the internal surface of the stock
rests on the mandril, which is supported at its ends, and the forging is carried out
by rotating the stock while feeding it, with the long side of the striker being
_ STAT
Operations
212
Declassified in Part - Sanitized Copy Approved for Release 2013/04/16: CIA-RDP81-01043R001900100003-3
Declassified in Part - Sanitized Copy Approved for Release 2013/04/16: CIA-RDP81-01043R001900100003-3
?
?
?
ptrillol to C.ta txis or the !'orginr.
(I) A combination or drawi,r out with a mandril ?Ind e'llr-ing on a mdndril. The
ezlArgi.g will correct the barrel-:1' iped:'e3s of t'le stoch, which before that was
upset and punched, and will increase the interral diameter to the required size; the
drawing out with a ma,dril will redpce the wall thickness and will increase the
dig. ILO
Fig.k1
length to the recrired size, Ville calibrating on the mandril the inner surface of
the forging at t.e same time.
e) '411en tie forging is to be tapered or conical,the drawinr out is eCfected by
wedge-like rollers (7ig.h1).
Punching is used to obtain a thoror-h opening in the forging (piercing), or a
ver:r deep impression ir the Cor,flin,-. When the punching is done b- hand, the.tools
used are: punches .(rou:A, flat, square, or shaped) and forms with correspondinr
, openings. When dere machine, the tools are: punch dies (solid with round or
shaped cross sections, also hollow dies), ekepieces (solid and hollow), calibrating
213
STAT
Declassified in Part - Sanitized Copy Approved for Release 2013/04/16: CIA-RDP81-01043R001900100003-3
Declassified in Part - Sanitized Copy Approved for Release 2013/04/16: CIA-RDP81-01043R001900100003-3
?
?
?
mandrils, backirg pieces with openings (backing rings). Punching will distort the
shape of the forged piece; the through punching (producing a hole) will produce
loss or waste of material in the form of the punched-out pieces.
(b)
- Method of Punching without Fig./3 - Method of Punching by Using
the use of a Backing Ring a Backing Ring
(a)- Start of operation; (b)- End of (a)- Start of operation;(b)- End of
1st stage; c - Start of 2nd stage operation
a) Striker; b) Punch die; c) 2nd eke- a) Striker; b) Punch die; c) Backing
piece; d) 1st punch die; f) Surplus ring; d) A prop; f) Punched-out
side of stock; g) 1st ekepiece piece
The consecutive operations for punching from both sides without thg use of a
backing ring is shown in Fig./1.2. The punching of one side with the use of a backing
ring is shown in Fir.43.
For large openings (over 500 mm), a hollow-punch die is used (see Fig.44).
Cutting. is done to obtain several smaller pieces from a single large piece, to
remove surpluses at the forging ends, to remove the added parts of the stock and of
the forginr:, and to obtain shaped forpings (crankshafts with throws cut out, draught
bars, forks, etc). Various methods of cutting out are shown in Fir.45.
The tools used for cutting are shown in Fig.46. For operations by hand, a
chisel (Fir.46a) is commonly used, also, ship hammers (Fig.46b). Tools used in
machine cutting are: axes (Fig.46c - two sides; 46d - one sided), angular axes
(Fig.A6e), semi-circular axes (Fil7.460 and several other shapes. In cutting, part
STAT
21h.
????
1
neclassified in Part - Sanitized Copy Approved for Release 2013/04/16: CIA-RDP81-01043R001900100003-3
Declassified in Part - Sanitized Copy Approved for Release 2013/04/16: CIA-RDP81-01043R001900100003-3
?
of the metal is lost i" forms of chips.
:3endinr is used to obtair. (directly, or ir combination with other operatiors)
a)
/ b)
?.-fl r--
-) I) (b) 5y (C)
Fig.44 - rethod of Purchinr with a .
-ollow Punch Die
(a)- 1st staFe;(b)- 2Ld stare;(c)-
of operation
a) Striker; b) 2rd ekepiece: c) 1st eke-
piece; d) Puz.c die: e) 3rd ekepiece;
f) Surplus side of stock; F) 7ackirg
411
rinr: h) A prop; i) Cle_r:l.rce 15-20 1;
j) Pus: ed-out rod
?
- Yethods of Cutting
a) Cut asurder; b) Cut-off
c) Cut-out
products of 7,ario-s e t (arFles, brlIces, nooks, 1,rackets, etc). DerdirT
distorts t:.e oriFi,a1 the cross sectiol, and decreases the area in tl.e zone
of the bend ('ir.L7). Ir addition, herding may produce folds in the inner contour
and cracks ir the orter. The probability of such defects is Freater when the. radius
of the roundness is small ard the angle of the bend is large. To prevent distortions
various tools are used: usnootEeners" in hard operations and rolls and strikers in
maeire work. These are or no help for correcting unfilled forms (reduced area iv
the zone of tle herd). To obtAr 1A-e desired area
in the zone of the bend, it is
made larger at this place before the operaLior. Several methods or bending are
shown in
215
? STAT
Declassified in Part - Sanitized Copy Approved for Release 2013/04/16 : CIA-RDP81-01043R001900100003-3
Declassified in Part - Sanitized Copy Approved for Release 2013/04/16: CIA-RDP81-01043R001900100003-3
Twisting is used to obtain forrinrs of a special shape (crankshafts with their
throws in different plares, wall bolts, stands, spiral drills, etc). The tools used
are: twisters (Fip.49), forks, plain
(d)
a)
(Fir.50) and hinged (Fir.51). To avoid
bending the wristpin during the twisting,
1717
4) v
c)
the following method is used: a) a strik-
(b) (C)
(e)
Fig.4A - Tools Used in Cutting
er is placed under the end of the shaft
and the stock is drawn to it by a chain,
(Fig.52), b) by a lunet (Fir.53).
Blacksmith welding is mainly used
in hand and machine forging of small
a) ?lade; b) Face: c) Sharpening angle;
pieces to be repaired. Soft steel con-
taininr 0.15 - 0.255 of carbon is very
rood for blacksmith weldirr, whereas steel containing more than 0.455 of carbon is
rot good for it. The welding ability of a steel by this method is lowered by the
d)The tail
Fir.47 - Distortions by Bendiar ir.hP - ending rethods
(a)- Of a round cross section;(b)- Of a a - 117 hammer; b - Py crane; c - With
rectarrilar;(c)- Reduced area . lower die and rollinr; d - In the
a) Reduction or area dies
1) Crane; 2) Rolling; 3) Upper die;
4) Lower die; 5) Die
-
21A
?
Declassified in Part - Sanitized Copy Approved for Release 2013/04/16: CIA-RDP81-01043R001900100003-3
Declassified in Part - Sanitized Copy Approved for Release 2013/04/16: CIA-RDP81-01043R001900100003-3
Fir.0 - Twister
,.50 - Rendirr with Plain r.'ork
7ip.51 - 9endinr with Finrod 7ork
a) Top position; b) Direction of
twisting roll; c) Yovement of lever
d) lottom position
Fir. 52 - Avoidirr gends Caused b'r
eirhts
presence of impurities.
The basic methods or blacksmith
weldint are; lap-weldinr (Fir.54), split-
end wladinr (ir.55), butt-weldinr (Fir.56)
and splint-weldinr (Fir.57) for thin
strips.
Latellr, besides Corrinp with hammers
and hydraulic presses, there is a widely
developed use of combined process of
forrinp and stampinr with crank-type
presses offered by A.V.Potekhin. The
basis of this combined forrinp-stampinr
process is the principle of dividinr the
technolorically complicated method of
preparirr the Corrinr irto separate simple
operations, carried out in a definite
consecutive order ir passes of forrinr
attachments, or in dies installed in the
crank-type presses.
!Tamer Stampinr. Oeneral inforMation.
'Iammer stampinr is mainl- done with open
dies and is accompanied with the formation
or burrs alorr the line or separation.
Latel-, however, there is a terdencv to
use special closed hammer dies which make
forrirr without burrs, makirr it possible
to reduce the co-sumption of metal.
In use are hacked dies and firmly
STAT
21?
Declassified in Part - Sanitized Copy Approved for Release 2013/04/16: CIA-RDP81-01043R001900100003-3
Declassified in Part - Sanitized Copy Approved for Release 2013/04/16: CIA-RDP81-01043R001900100003-3
?
secured dies. Stamping with backed dies is done by forging hammers and is used when
a small quantity is to be fabricated. The firmly attached dies are used in special
Fir.53 - Twisting bv Using a Lunet
d)
Fir.54 - Lap Welding
a) Upset end; b) Forging the facing;
c) Welding; d) Smoothening
stamping hammers for mass production, or when handling large quantities. The final
configuration can be imparted only to simple forgings to be made from bar stock
(such as square, round pieces, and rarely -
strips). In most cases, it is necessary to impart
to the stock a shape verr near to the configura-
tion Lf the finished forging.
When handling small quantities, these prep-
aratory operations can be effected by free forg-
ing. In mass production, however, or when handlinE large quantities, they are
effected with the aid of preparatory dies. For this purpose, all recesses and all
changes in the shape of the stock can be effected by a single stamping block (cube)
bv means of a so-called multipass design. It is the most widely- used method.
Lately, however, with mass production in view, the practice is for a transition,
or for a group of transitions, from ore device to anether. In this manner, the
forging MdT be effected with two or more hammers, or on with a combination of sev-
eral devices, such as a hammer and forging rollers, horizontal forging machine and
a hammer, etc.
Pir.55 - Welding of Split End
Declassified in Part - Sanitized Copy Approved for Release 2013/04/16: CIA-RDP81-01043R001900100003-3
STAT
Declassified in Part - Sanitized Copy Approved for Release 2013/04/16: CIA-RDP81-01043R001900100003-3
Corsiderable simplificatior of the stampirr process, and at the same tire, an
increuse ir procluctivit-r, sav-r.nr or metal and improvement in the quality cur he
-t c p.:riortic rail o' steel-, the cross section of
- r'utt eldinr
a - ''efore weldirr-; b - After
weldirr; c - After smootherirr
- Splint Weldinr
a - ds ready for weldirr;
h - Weldinr-
alorr its is rot uriform (7ir.50.
In mar: clses, t:c ,pplic_tior of the rollirr process for special profiles
.59) offers alvart:,res. The stock is c- t, preferabli h- shears, into pieces,
It car ')e for ore foriinr, or for
two, i.e., ore Cor-in; to be followed by
another 11.- ti:rninr the piece. It clx
also he el't for several for-di-Fs (for,-
in-s from 1 1-)10, ir this caso,
fi:ishedL'or-i1:- is ("1:t b-r Lh.,1 "hrire"
of tie lie (nP11.37), 1).
Latel-, Ue use o: stock in form
of "icaills" is widespread, as in tli:;
Corn it JUVO3 netal due to the fact that
7ir.5PFir.59
there are no snithton,s to be used on
Ar! portion 0r the stock. jtock, ir. the Corn or several rorginrs-to-bel is prepared
for, ,-orrirrs of less than 300 nm long and weirhts of 1-ss thar 2.5 kr. Stock, in
the form of "twins" is used for forrirrs up to 400 nm in length and 3 kr ins-rAiit.
Declassified in Part - Sanitized Copy Approved for Release 2013/04/16: CIA-RDP81-01043R001900100003-3
Declassified in Part - Sanitized Copy Approved for Release 2013/04/16: CIA-RDP81-01043R001900100003-3
?
?
Larger forgings are forged singly (Bib1.1).
Stampirg 'iammers. Stamping with firmly attached dies is done, in most cases,
by steam ard air operated hammers in a two-column frame. These are double-acting
Table 18 Table 19
Specificatiors Cor Steam ard Air Oper- Specifications for Friction-Tppe Pam-
ated StampinF "amrers (from COST mers with Board (from COST 957-h1)
7021-5h)
a)
b)
C)
d)
e)
f)
g)
0,63
1000
180
403
380
600
7,5
1
1200
220
500
450
660
11
1,6
120.)
260
550
600
800
ii
,
12(X)
2(30
6(X)
700
900
13
2,5
1250
300
611)
700
910
21
3,15
1250
350
7(10
800
1 ()0 )
25
4
1250
400
700
900
1100
31
5
1300
400
700
1000
1200
37
6,3
1300
400
751)
1000
120')
42
8
14(x)
450
f)04)
1100
13 )0
-
10
1400
450
10(X)
121)0
1400
-
12,5
1500
500
1100
1.100
1500
-
16
1500
500
1200
1500
1600
-
a)
b)
C)
d)
e)
1)
from
to
500
WV
1400
HP
450
&V
&V
750
WV
1450
220
500
*V
651)
IWO
WO
!CV
720
550
450
700
1500
900
1500
260
No
600
600
a) Weight of falling part in m; a) Weight of falling part in kg;
b) Length of stroke ir mm; c) Least b) Length of stroke in ram; c) Least
height of dies without tails in mm; height of dies in mm; d) Distance be-
d) Clearance between ruides in mm; tween guides ii-' mm; e) Size of.ram,
e) Size of ram; from front to back, in mm; from frort to back in mm; f) Size of
0 Size of die holder, from front to
back in mm; F) Weight of hammer, without
anvil block in m
die holder from front to back in mm
hammers with an upper cylinder (FiF.A0). Also, by friction-type hammers with a
board (Fig.61). Considerably less in use are steam and,air operated hammers with
- _STAT
220
Declassified in Part - Sanitized Copy Approved for Release 2013/04/16: CIA-RDP81-01043R001900100003-3
..???
lower c ard Prictiot?t.:ype hammers with belts or ropes. Lately, hammers
with WO raMt3 are eXtellSiVel%' I1Sed for larre forrinr:3; the movement of the rams is
opposite to e Leh other (Fir. ;2).
7ig.'0- Steam and Air Operated
Fir.61- Friction-T.ype
Fanner with r3oard
Specificatiors for steam and air operated hammers are shown ir Table 18, and
for friction-t-pe flammers - in Table 19.
is a ruide, the followinr data may be used to determine the productivity of
.stampinf hammers:
Declassified in Part - Sanitized Copy Approved for Release 2013/04/16: CIA-RDP81-01043R001900100003-3
221
STAT
Declassified in Part - Sanitized Copy Approved for Release 2013/04/16: CIA-RDP81-01043R001900100003-3
Declassified in Part - Sanitized Cop Approved for Release 2013/04/16: CIA-RDP81-01043R001900100003-3
?
?
?
Weight of falling part in mm
0.5
1
2
.
3
Productivity per hr in kg
120
250
550
750
Weight or falling part in in
h
5
6
--
9
Productivity per hr in kg
1200
1500
1800 _
2500
The relationship between the weight of falling parts and the weight of forgings
is shown in Table 20.
Table 20
Orientation Data on the Relation between the Required Weight of the
Falling Parts of the Hammer, the Area of the Groove for Burrs and
the Weight of the Forging (Bib1.7)
a)
b)
C)
. .1-0,5 0,5-2 J 2-3 j 3-12 12-25 J 25-40
E00 1000 1500 2000 3003 7000-10 000
1,2-1 ,7
1.7-2A
2,4-4.2
4,2-5,3
5,3-11,2
a) Weight of forging in kr; b) Weight of falling parts of hammer in kg;
c) Area of cross section of the groove for the burrs in cm2
Weight of Stock for Hammer Stamping. The weight of stock Gis is represented
approximately by the following equation: Gis = Gpk + Cz + Our, where Gpk is the
weight of the forging; Gz is the loss due to burrs; Gug is the loss due to burning
during the heating.
The lost weight due to burrs can approximately be found from the equation:
z (0.5 - 0.8) y Sfz
where y is the specific weight of the metal; S is the perimeter of the forging
STAT
222
Declassified in Part - Sanitized Copy Approved for Release 2013/04/16: CIA-RDP81-01043R001900100003-3
Declassified in Part - Sanitized Copy Approved for Release 2013/04/16: CIA-RDP81-01043R001900100003-3
measured alorr the line of separatior of the dies; f, is the area of the cross sec-
tior of the'rroove for the burrs. For forrinrs with complex confirarations, the
value of the coefficient s:-ould 'ze lar-e. Values for the area f, are river in
Table 20.
The loss due to burrinr durirE the
'1 ? heati, r,ur is assumed to equal 2:1 of
; ni
I 1'
?-1,.--.. the forrinr weirht.
,I..._ ...,,,
.,, N----,.
, -e--=1.
?....._,, ...z.,k.?!_ by tors and to cuttinr of the stock arc
Losses of metal due to handlinr
.-7,-%-,--,Vo.A=L'...
(-!e -/o
I 1-:el://,1:r---
J1 N C.,
I F .. rt
'1111\
- - - i not included in the r.- shown above.
' iv
1 1 1
?
1
V
,
'
11;11
, .. /...
f II,ii
I , 11,11,
../..../ IIIII ,
Re
II
ou ? 1,11
..? 1.:1 11.11
i* *-. -.P.
Ji
-, ....4.-4;hwirr404.44.,_14..,... ?;444.444.... 4..... .....4.44 ...i.v.roi.i
Sizes of Stock: a) 'or forrinr by
upsettin-, the butt end, the lenrth and
the cross sectio: of the stock Yave the
same val'les as ir free forrinrs opera-
tions (see earlier in text).
b) The cross section of the stock F.
is
for all other shapes, where the cross-
sectional areas of the portions of the
stock do not differ much, may be found
Fir.:2 - "Irmer without Anvil lock by usinr the followinE equation:
(1 05 1,3) ilk
Fis
L?
w'.-.ere 7. is the volume of the stock; Lpk is the lenrth of the forrinp.
is
;:here, llonr the lerrth of the forrinr, cross-sectional areas of different
portions differ sharpl:', some of these portions have to be drawn out. In such a
case, for the pLrpose of orieLtation, the cross section of the stock may be assumed
as eval to:
223
STAT
Declassified in Part - Sanitized Copy Approved for Release 2013/04/16: CIA-RDP81-01043R001900100003-3
Declassified in Part - Sanitized Copy Approved for Release 2013/04/16: CIA-RDP81-01043R001900100003-3
?
F= (0,7 ? 1) F max,
where 7 is the maximum cross section of the forrinr, including the cross section
MaX
of the burrs, equal to 2.(0.5 - 0.8)fz.
The second equation is used in cases when calculations show that the cross sec-
tion of the stock calculated by using the first equation turns out to be:
1.5 S (Fig.155). The minimum width of the product is ..13 >, 1.5 S.
In bent and drawn?out parts, the distances from the edges of the holes to
the walls must satisfy the following conditions (Fig.156):
295
STAT
Declassified in Part- Sanitized CopyApprovedforRelease2013/04/16 ? CIA-RDP81-01043R00190o1onnrn_?1
Declassified in Part - Sanitized Copy Approved for Release 2013/04/16: CIA-RDP81-01043R001900100003-3
?
?
x Rp + 0.5 S
tv RN + 0.5 S
t R +0.5S
g 6
The minimum dimensions for nonferrous alloys when chopped out by a rubber
die, and when S = 1.3 mm, should not be less than 150 mm.
Table 39
Minimum Radii of a Contour Consisting of Straight and Curved Lines
when Punched or Chopped by Ordinary Dies
Operation
Angle cc at the
Joint of Lines in ?
HATUMinapPer,
Soft
aeel
Alloyed
,
Minimum Radius of Contour, in Fractions of S
Chopping
> 90
_
< 90
0.18
0.35
0.25
0.5
0.35
0.7
Punching
> 90
_
'90
0 2
04
0.3
0.6
i
,
0.45
0.9
Data for Designing Shape-Changing Operations. The mechanical properties of
the material in the bending zone undergo a change.
The nature of the change in the basic mechanical properties for Grade CT steel
and with S = 28 mm and R = 25 mm may be seen in Fig.157.
In .a cold bending operation, the zone of critical deformations for different
ratios of ?g- is shown in Fig.158. A part subjected to cold bending first, and
to heating after, will age considerably in the bending zone, which results in
brittleness. Therefore, no welding should be done near the zone of cold bending.
Both the cross section and the dimensions of the original stock undergo a
change in the bending zone. The nature of the change is shown above in Fig.127.
When using dies for shaping angles, braces, small and medium sized shelves,
the precision depending on the thickness of the material may reach the following
STAT
296
Declassified in Part - Sanitized Copy Approved for Release 2013/04/16: CIA-RDP81-01043R001900100003-3
Declassified in Part - Sanitized Copy Approved for Release 2013/04/16: CIA-RDP81-01043R001900100003-3
?
precision Values 01izd)
S in mm ... up to 2
S 28;
Fig.157
a) Originally; b) Outer fibers;
c) Inner fibers
from 2 to 4 above 4
? 0.3
? 0.4
Fig.158
31-ctz
When bending a brace, wrinkles will appear in that portion, where the round-
ness changes into a vertical line, also the thickness in that place will be Sl< S.
The wrinkles and the decrease in thickness may be remedied only by additional oper-
ations, which may increase the thickness to S1 S.
The height H of the straight portion of the bent wall (shelf) should satisfy
the condition H > 2 S. If a lower height is necessary, provision should be made
for impressing a groove (see right side of Fig.159), or an allowance should be
made (by means of surplus material) for the mechanical treatment after the stamping.
When shaping the contour of a bent part, and if the axis of the bend is above
the shelf (Fig.159, left side), local cut-outs should be provided. The dimensions
of these cut-outs 'should be a r-t: S and b > S. ' If the axis of the bend is outside
the limits of the shelf, (Fig.159), in this case no cut-outs are needed.
297
STAT
Declassified in Part - Sanitized Copy Approved for Release 2013/04/16: CIA-RDP81-01043R001900100003-3
Declassified in Part - Sanitized Copy Approved for Release 2013/04/16: CIA-RDP81-01043R001900100003-3
?
?
The thickness or the shelf S of an open brace having an angle g = 900, if
necessary, may be less than the thickness of the base (ST < S); for steel; in this
case, the decrease in wall thickness should not exceed 30%, i.e., ST > 0.7 S.
Complex shapes, which are not practical for drawing operations, should be,
' inasmuch as possible, simplified, or
separated into simple portions, to be
'joined later by stamping, welding or
riveting, so as to obtain the required
complex shape (see Fig.179, below).
The volumes of hollow vessels should
shape themselves with their dimensions,
decreasing towards the bottom. The
draftsman should indicate on the
drawing which of the dimensions are re-
quired - inner or outer.
For complex parts it is necessary to work out a technological basis for the
holes, external parts of the contour and other elements of the design.
In a drawing-out operation, the wall thickness is actually not equal to the
thickness of the original part. This thickness may be determined, approximately,
from the curves of Fig.129.
When drawing out a part having a large surface, heaps (hillcocks) may be
formed. To avoid this, the flat surface may be made more rigid by means of long
and intersecting ribs. Closed and symmetrical ribs are better.
Butt welding should be widely used for ring-shaped parts, regardless of the
cross section of the ring, whether it is simple or complex.
In drawing out a rectangular-shaped vessel, the transition of the bottom to
the side wall may be shaped without using a single large radius, instead of that,
it may be done with a slope of 45? together with smaller radii for the transition
STAT
44
Fig.159 - Location and Dimensions
of the Cut Outs and of the
Groove
298
Declassified in Part - Sanitized Copy Approved for Release 2013/04/16: CIA-RDP81-01043R001900100003-3
Declassified in Part - Sanitized Copy Approved for Release 2013/04/16: CIA-RDP81-01043R001900100003-3
;
of this slope to the walls and to the bottom.
If cracks are formed in the angles of a vessel being drawn out, parts of the
angles of the flat original stock should be cut off.
The radii of drawn-out parts should be in conformity with the equations
quoted before. Decreasing the radii at the expense of a more complex process may
be done within the following limits:
Fig.160
Fig .161
a) Contour of the
? stock
Radiu6 of the bottom R > 0.1 S
Radius of the flange R > 0.2 S
A further decrease of the radius
to R = 0 is also possible, but the decis-
ion is with the designer, as shown in
Fig.160 (left - typical shaping of a
thin material, right - of a thick mater-
ial). The relation between the values
are: 1)1 = 2 - 5 marq = 0.1 - 0.3 S;
R> S (but not less than 1 mm); h > S
but not less than 1 mm); b > 2 S (but not
less than 2 R). In drawing out of parts with a warped cross section and with
rounded and straight portions (Fig.161), the height h of the inner walls in the
transition zone of two straight portions, should be such that > 0.6. The
R -
height H of the straight portions, is not limited in the outer wall, but in the -
inner wall it is limited by the amount of metal-in the middle portion of the pro-
duct.
In a drawn-out product, the contour of the flange (especially if its outlines
are complex) should be shaped by an equidistant curve. The width of the flange
should be 'small, but not less than Ri4 + (3 - 5) S.
Round bodies (medium and large), which are hard.for die drawing should be
STAT.
299
Declassified in Part - Sanitized Copy Approved for Release 2013/04/16: CIA-RDP81-01043R001900100003-3
Declassified in Part - Sanitized Copy Approved for Release 2013/04/16: CIA-RDP81-01043R001900100003-3
?
pressed out on a lathe. As a result of compression, the deviations in dimensions
for a diameter up to 500 mm will be in the order of 0.3 mm; with a diameter
above 500 mm the deviation may be from 0.3 to 0.5 mm. When the depth of the product
is large, the allowance may be increased by 0.2 - 0.3 mm.
The building in of rigidity in thc'angles of a body being stamped is shown
in Fig.162. When R has its maximum value, the elongation of the material, in the
Fig .162
a) Section SS; b) Section BB
concave or convex portions, should not exceed 1.2 - 1.4 E
In drawing-out parts with edges of moderate heights, but also with unfavorable
dimensions, folds will be formed on the edges. The formation of folds may be
avoided by removing the excess material in the cut up (cutting-out triangles -
Fig.16j).
Ring-shaped hollow products, when designed may be shaped differently
(Fig.164).
From the standpoint of technology, the variation 1 is best. A ring
made up of two halves (variation 4) is easily produced, but, in this case, the
waste of metal will be great.
Methods of Assembly. The design and ease of operation of assembled parts
determine, to a great extent, the quality of performance and the cost of a machine.
The stamping process has great possibilities in this direction. As a rule, stamp-
ing is used for assemblies which are not to be taken apart. With its help
iSTFAI s
300
Declassified in Part - Sanitized Copy Approved for Release 2013/04/16: CIA-RDP81-01043R001900100003-3
Declassified in Part - Sanitized Copy Approved for Release 2013/04/16: CIA-RDP81-01043R001900100003-3
?
?
obtained by different technological methods (sheet metal work, volume stamping,
cutting, etc) may be assembled.
Sketches of various assemblies are shown below, also shown are some of the
methods applied in stamping.
Figure 165 shows the.method of pro-
ducing rectilineal and ring-shaped seams
(locks) used for joining parts. For Some
71(11:-1 -17>2
of the joints (seams) point welding or
45C71.1._. riveting is used. One group of seams is
concerned only with hermatically tight
Fig.163 - 1 - The Con-
tour of Flat Stock;
2 - Contour of the
finished part;
3 - Metal portions
to be removed
Fig.164
joints, others combine it with strength
and rigidity of the joint.
Various joints used for joining
sheet metal products are shown in
Fig.166. The formation of the angle of a
sheet metal box (obtained by bending -
not by drawing out) is shown by
sketches a, b, c. The sketch d is shown as an assembly of three stamped parts.
The box shown by sketch e may be obtained by bending a cut-out sheet.
_ Figure 167 shows a variety of sheet metal parts joined together. Shown are
designs combining several flat parts, round bodies with flat parts and, finally,
combining round bodies with,rbund bodies.
Several methods of joining sheet metal parts are shown in Fig.168. For these
methods, as a rule, are used bending, edging and shaping.
Figures 169 and 170 show-examples of joining sheet metal parts with parts
obtained by cutting. In the main, such parts have been formed by bending and
shaping.
In Fig.1710 a to c give an idea about designing of an assembly of bushings
STAT,
301
k.6
Declassified in Part - Sanitized Copy Approved for Release 2013/04/16: CIA-RDP81-01043R001900100003-3
Declassified in Part - Sanitized Copy Approved for Release 2013/04/16: CIA-RDP81-01043R001900100003-3
Declassified in Part - Sanitized Copy Approved for Release 2013/04/16: CIA-RDP81-01043R001900100003-3
Declassified in Part - Sanitized Copy Approved for Release 2013/04/16: CIA-RDP81-01043R001900100003-3
1) Partial spreading of the ring;
Declassified in Part - Sanitized Copy Approved for Release 2013/04/16: CIA-RDP81-01043R001900100003-3
Declassified in Part - Sanitized Copy Approved for Release 2013/04/16: CIA-RDP81-01043R001900100003-3
????
?
?
?
(obtained by cutting) with sheetmetal parts. In sketches d and e, it is evident
that for an assembly the material may be deformed not along the continuous contour,
but only partially.
Figure 172 shows examples of designing an assembly of rod-shaped material
with sheet metal parts.
WELDED STAMPED PARTS
Welded stamped parts, resulting from the application of two processes - welding
and stamping - have the following features:
1) Sheet metal stamping reduces the number of parts going into a welded stamped
product (the method - bending);
2) Sheet metal stamping reduces the length of welding seams (the method -
bending);
3) Technologically, welding raises the quality of sheet metal stampings.
General
The features of welded stamped parts and the problems to be solved when de-
signing the parts are:
1. Imparting any complex shape (required by the designer)tO the parts,- or to
the finished product, is, in majority of cases, easier to accomplish by welding ?
of the component parts, the shape and dimensions of which may be relied upon to
produce the required configuration. More often, these products are stampings (in
sheet form or voluminal bodies), but they may also be from castings or from rolled
material of certain grades.
Welded stamped products may be a combination of component parts produced by
different methods (stamping, casting and rolling).
2. The technology of welding and of heat treatment is so perfected that most
of the grades of structural steel maybe welded with confidence.
304
STAT
Declassified in Part - Sanitized Copy Approved for Release 2013/04/16: CIA-RDP81-01043R001900100003-3
Declassified in Part - Sanitized Copy Approved for Release 2013/04/16: CIA-RDP81-01043R001900100003-3
?
3. Welded stamped products are lirht in weight. This is effected by using
quality material instead of castings and rolled metal having a higher fluidity and,
also, by making the cross sections equal in strength. When changing from cast in-
gots to welded stampings, a reduction in weight is accomplished averaging 20 - 30%
' when changed from steel, and much more, compared with cast iron.
4. Welded stamped parts will insure stability of operation, though the machine
may be loaded to a maximum. To do this, the design of the parts should consider,
above all, the requirements for rigidity.
5. The possibility to combine in one assembly raw and heat treated metals,
and also to combine in one assembly several different metals. Such possibilities
open a new field for designers and technicians.
6. Welded stamped products are not limited because of dimensions.
7. The stamped components of a welded stamped product make it possible to
increase the strength by a favorable arrangement of the fibers which, as a rule,
do not cross each other.
8. ''Welded stamped parts from thick sheets may have allowances in the form of
excess material, if necessary, and may have the same tolerance (for precision) as
have voluminal stampings.
Technological Classification of Stamped and Welded Material. Stamped and
welded products are, divided into the following groups:
1. Stamped-welded stock which is not subjected to cutting after the welding.
2. Stamped-welded stock which, after welding, has part of its surface, or its
entire surface subjected to a cleaning operation by cutting.
3. Stamped-welded stock which after welding has part of its surface, or the
entire surface subjected to both, a rough and a final cleaning operation by the
method of cutting.
Stocks of the first group, except in rare cases, should not be used if they
are to be made into parts requiring great precision.
305
STAT
Declassified in Part - Sanitized Copy Approved for Release 2013/04/16: CIA-RDP81-01043R001900100003-3
Declassified in Part - Sanitized Copy Approved for Release 2013/04/16: CIA-RDP81-01043R001900100003-3
0
? 3. Welded stamped products are light in weight. This is effected by using
quality material instead of castings and rolled metal having a higher fluidity and,
also, by making the cross sections equal in strength. When changing from cast in-
gots to welded stampings, a reduction in weight is accomplished averaging 20 - 30%
' when changed from steel, and much more, compared with cast iron.
4. Welded stamped parts will insure stability of operation, though the machine
may be loaded to a maximum. To do this, the design of the parts should consider,
above all, the requirements for rigidity.
5. The possibilityto combine in one assembly raw and heat treated metals,
and also to combine in one assembly several different metals. Such possibilities
open a new field for designers and technicians.
6. Welded stamped products are not limited because of dimensions.
7. The stamped components of a welded stamped product make it possible to
increase the strength by a favorable arrangement of the fibers which, as a rule,
do not cross each other.
8. Welded stamped parts from thick sheets may have allowances in the form of
excess material, if necessary, and may have the same tolerance (for precision) as
have voluminal stampings.
Technological Classification of Stamped and Welded Material. Stamped and
welded Ooducts are divided into the following groups:
1. Stamped-welded stock which is not subjected to cutting after the welding.
2. Stamped-welded stock which, after welding, has part of its surface, or its
entire surface subjected to a cleaning operation by cutting.
3. Stamped-welded stock which after welding has part of its surface, or the
entire surface subjected to both,. a rough and a final cleaning operation by the
method of cutting.
Stocks of the first group, except in rare cases, should not be used if they
are to be made into parts requiring great precision.
305
STAT
Declassified in Part - Sanitized Copy Approved for Release 2013/04/16: CIA-RDP81-01043R001900100003-3
Declassified in Part - Sanitized Copy Approved for Release 2013/04/16: CIA-RDP81-01043R001900100003-3
0
?
?
Technolopical Requirements for Stamped-Welded Parts. When designing such parts,
the shape, dimensions and the materials of each component element and of the fin-
ished product should be in conformity with the technological requirements for
efficient stamping and welding.
. Fig.173
a) Welded
Fig.174-
The technological requirements for stamping were described in the preceding
pages. Requirements for welding are described in Chapter III.
EXAMPLES OF STAMPED-WELDED PRODUCTS
.Below is shown a variety of stamped-welded parts made up mostly from sheet
metal.
Figure 173 shows two variations of the same part - of a limiter. The sketch -
to the left is from a stock which his undergone volume stamping, and had its surfaces
treated by cutting all around. The sketch to the riglit is an example of the ad-
vantage of combining stamping with welding. In thii case, cutting is limited to
drilling and broaching the hole, meaning a lower cost.
The stamped-welded plate in Fig.174 consists of three separate parts 1, 2, 3.
The welding seams are not continuous. After the welding and annealing, only the
butt ends and the holes of part -3 are treated by cutting.
In Fig.175. are shown two variants of the same device - the movable part of a
feeding mechanism. The device shown in Fig.175a was produced by volume stamping,
.STAT
306
Declassified in Part - Sanitized Copy Approved for Release 2013/04/16: CIA-RDP81-01043R001900100003-3
Declassified in Part - Sanitized Copy Approved for Release 2013/04/16: CIA-RDP81-01043R001900100003-3
.i.e., all of its surfaces have undergone an all-around finishing operation by cut-
ting. The stamped-welded variant is shown in Fig.175b. It consists of a body (1)
and a supporting piece (2). The cut-up
of these two parts and the places finished
by cutting are shown in Fig.175c. The
guiding projections a and the planes d,
serving as bases for the pins and as sup-
!
! ports, are alike for both variants of
the device.
Figure 176 illustrates a practical
and an intractable (from the standpoint
of technolopy) design of the same device.
2
Variant a consists of part (1) having a
closed deep impression (hard to finish
by cutting), part (2), which is bent and
Fig/175
of part (3), also hard to finish by cut-
(1) Cut-up; (2) Excess material for
ting. In variant b, parts (1) and (3)
treating surface by cutting
require no special effort for finishing;
and a pin is used-to prevent the displacement of the part located in the recess of
-portion (1). The joined parts in both variants are replacable.
In Fig.177, to the left, is shown a cast support for a shaft which is arc-
welded to the cheek of the sheet metal base. The sketch to the right shows the
shaft support made from Welded sheets consisting of a bent sheet metal box (1),
(for the purpose of rigidity) which is point-welded to the cheek of the base and
to part (2), which in its turn is arc-welded to the cheek-of the base and to the
rigid box., In this cape, the use of stamping-welding insures a better and stronger
assembly and simplifies the production.
PI:pure 178 shows'a stamped' welded and soldered head Of a gaeoline engine
STAT
307
Declassified in Part - Sanitized Copy Approved for Release 2013/04/16: CIA-RDP81-01043R001900100003-3
?
cylinder block. Standard sheets having a thickness of 3, 5, and 10 mm.
done by hand, welding of parts has more advantages than producing the entire part .
Fig.176
Fig.177
a) Shaft support; b) Drilled holes;
c) Cheek of the base
by casting. The advantages are shown below (for a head of a cylinder block):
Index
By casting
the head
_
By stamping
and welding
I.
Saving
in %
Net weight
Time consumed
Cost, in rubles
8.15 kg
30.4 min
13.5
5.75 kg
22.5 min
10.3
29.5
26
23.7 ...
- Figure 179 shows the design of an assembly subject to strenuous operations.
In this assembly, considerable, stresses are transferred frail the tube to the cup. -
To avoid the possibility of the cup becoming 'wrinkled, it has a belt consisting of
? two flanges welded to the bottom edge of the tube. To make the welding easier,
the edge of the tube is bent somewhat. The cup is made of two halves, each of.
which maybe produced by drawing it out not too deep. This enables the use of a
material that must not fulfill all the requirements of a material used. for deep
drawing.
An example of the full, utilization of stamping-welding methods is the bed of
STAT
Declassified in Part - Sanitized Copy Approved for Release 2013/04/16: CIA-RDP81-01043R001900100003-3
308
Declassified in Part - Sanitized Copy Approved for Release 2013/04/16: CIA-RDP81-01043R001900100003-3
Declassified in Part - Sanitized Copy Approved for Release 2013/04/16 : CIA-RDP81-01043R001900100003-3
-
SI
?
?
?
a lathe.
. .
To design the bed, attention was paid to the requirements for the planes join-
ing each other and to the loads to be ex-
perienced by the bed. Technologically,
the design of the bed is very simple and
the bed itself is rigid and sturdy.
a)
420C:ai
' b)
The drawing of the lathe bed is
shown in Fig.180.
The bed is made up?of welded sheets,
with all sheets of the same grade, namely
steel Grade CT 2. The sheets joined
longitudinally have a thickness of 3 mm.
The transversely located baffles are 5 mm
a) Section AA; b) View along B
in, thickness. Because of the possibility
of using sheets of only a few thicknesses and due to the practical shapes and
dimensions, the coefficient of utilization of material may be raised by 20 - 30%,
as compared with the coefficient of metal
utilization by ordinary stamping without
? welding. .
.The stamping-Welding method in-
creased the rigidity of the bed. Because
ttttttttttttt ,40?0%..00?4
:75--.5.?E!SM.17r
of this, only three supports were found
to be necessary. The feature of this
design is the 'almost complete lack'of
preparatory work to make the borders fit
T F = 5
117-
8
Fig .l7
Fig.179
for welding.'
Finally, the Mechanical treatment is reduced to a minimum by fabricating the
front guide from rolled sheet with one profile and the back guide from rolled sheets
STAT
309
Declassified in Part - Sanitized Copy Approved for Release 2013/04/16: CIA-RDP81-01043R001900100003-3
Declassified in Part - Sanitized Copy Approved for Release 2013/04/16: CIA-RDP81-01043R001900100003-3
?
?
' of a different profile.
COLD UPSETTING OF PARTS BY AUTOMATIC PRESSES
?
A great variety of small parts used for joining or to strengthen other parts
' may be produced by automatic presses designed for cold upsetting such as wheel
Br
t
t
A
?
t I
,11 -7
-????
a)
Fig.180 - A Stamped-Welded Lathe Bed
a) Section along AA; b) Section. along BB
spokes, cap nuts, several types of connecting pins, valve tappets and their
adjusting bolts, small rollers-and balls, star-shaped devices for controlling
brakes, special supports for containers used in the vegetable induitry, spokes for
bicycles and motorcycles, caps and many others (Fig.181). Cold volume stamping
arid upsetting will produce parts with a higher 'degree of precision and with better
finished surfaces than is possible in hot stamping. On the other end, cold upset-
ting requires a Sturdier and more powerful equipment.
310
STAT
Declassified in Part - Sanitized Copy Approved for Release 2013/04/16: CIA-RDP81-01043R001900100003-3
Declassified in Part - Sanitized Copy Approved for Release 2013/04/16: CIA-RDP81-01043R001900100003-3
As a rule, cold upsetting is effected without producing extruding edges (so?
called: flash, fins or burrs).
The production of the above?named parts by .the automatic presses using pres?
sure on the unheated parts, instead of cutting out the shape, is resulting in
great savings of metal, in a tenfold increase of productivity; and in improvements
of such properties as firmness and hardness.
[11
t
4e3'WI
rl

Fig.181 ? Samples of Parts Produced by Cold Upsetting in an
Automatic Press
In this cold process using pressure, the fibers do not cross each other, 'but
are oriented along the contour.
The maximum diameter of a rod which may be handled by this cold process in
automatic presses is 25 mm. As to, the maximum length, it is not as yet possible to.
make it higher than 2op mm for standard presses, but specially designed presses are
able to handle lengths up to 400 mm. With semiautomatic and automatic stamping
serving as a preliminary operation, it is possible to do the heading (upsetting)
the heads), reducing and threading on pieees with a length up to 1800 min:
311
STAT
Declassified in Part - Sanitized Copy Approved for Release 2013/04/16: CIA-RDP81-01043R001900100003-3
Declassified in Part - Sanitized Cop Approved for Release 2013/04/16: CIA-RDP81-01043R001900100003-3
? Metals Used in Cold Upsetting
The metal used for cold upsetting of parts has, in most cases, a round cross
section with a diameter from a few tenths of a mdllimeter up to 25 Mt with a toler-
ance of 0.025 to 0.15 mm.
In isolated cases, the material may have a larger diameter and be not only
round but have a different shape, such as rectangular, square, trapezoidical or
oval.
Mostly used are: Grade 08 to 45 quality carbon steel and Grades Al2 to A35;
Grades of alloy steels used are: 35G2, 20X, 40X, 40XH, 151, 25XHBA, 40XIA, 40XHM,
30XGCA, SHX9, 1X18H9T, T10A, Tl2A, and others; alloy nonferrous metals such as
Duralumin D3P and DI; brass 1559, L62, 1.68; red copper; Monel metal, etc.
The metal used for cold upsetting has a good plasticity if its hardness HB
-after annealing is: HB = 120 - 207. For told upsetting, usually, in use are steels
with relatively large grains corresponding mostly to grains No.3 and No.4 out of
eight grade numbers.
Grains of such size are in conformity with the plasticity of the steel required
In upset operations.
The relation between the chemical composition and the properties of steel is
described in Table 40. For the Physical and mechanical properties of a calibrated
wire, see Table 41.
, A characteristic graph of a.test with calibrated wire, stretched and cold-
drawn, is shown in Fig.182. .
The metal for cold upsetting having a diameter up to 16 is delivered in
bundles; metal of a larger diameter is delivered in lengths up to 6 1.
The surface of the calibrated material must be smooth, shiny, without shells,
cracks and .other similar defects. .
The outside diameter of a bundle is Dout 100-750 .mm, while the inside diame-
of the bundle, depending on the diameter STAT ,
312
?
,o
Declassified in Part - Sanitized Copy Approved for Release 2013/04/16: CIA-RDP81-01043R001900100003-3
Declassified in Part - Sanitized Copy Ap?roved for Release 2013/04/16: CIA-RDP81-01043R001900100003-3
JO
18
20:j
29:Di
?
?,.
34
36__
4
Table 40
The Influence of the Chemical Composition on the Plastic Properties
of Steel in a Cold Upsetting Operation
Chemical
Element1
? Improves
Makes
WOr se
1 Additional Information
C
+
i
Increasing C by 0.1% will increase Ov
by 6-8 kg/mm2. Cold upsetting of carbon
steel containing C> 0.2% requires anneal-
ing to a structure of greatest plasticity
.- grained perliti.
_
Si
?
A
+
In a steel containing 0.45-0.5% carbon,
Ithe Si, if present, has very negative
iresults on cold upsetting. The presence
!of Si> 0.2% lowers to a great extent the
iplasticity, causes a considerable heating.
of the metal during the deformation, reduce
the firmness of the dies and requires a
greater force for upsetting.
Mn
+
In carbon steel, the Mn content should not
lexceed 0.65%. The presence of Mn is i dic-
tated by the necessity the unfavorable
effect of S
Cr
+
The presence of Cr lowers the plasticity
of high carbon steels. Increasing Cr
by 0.1% in steel Grade 40 will increase
av by 2.5 kg/mm2. For steels containing
less than 0.3% carbon, the presence of Cr
has no great effect. - .
W
?
+
.
?
,The admixture of 0.15 - 0.2% improves the
cold upsetting and increases aT and av,
at the same time. .
Mo, V
+
Improves the cold upset process and imp-
proves al, and av
Al
.+
Steel, with 0.03 - 0.05% of Al added as a
deoxidizer, has high plastic qualities
and tends to become
4 grained pearlite.,
313
STAT
5
Declassified in Part - Sanitized Copy Approved for Release 2013/04/16: CIA-RDP81-01043R001900100003-3
Declassified in Part - Sanitized Copy Approved for Release 2013/04/16: CIA-RDP81-01043R001900100003-3
(- I
material, is G = 30 - 80 kg.
Cold upsetting is -delivered in. annealed_or_normalized_condition*
etched by a weak acid solution and neutra-
Steel for
a)
b)
26 ? Fig.182 - Characteristic Graph of a
1
J '
Test Performed by Stretching Two
Calibrated Cold-Drawn Wires
1 - Steel wire with a diameter of
5.1 ms, with (al. 64.8 keim2, HB =
= 152); 2 - Brass wire, 5.1 MIR in
diameter, G T -I-. 38.4 kg/2, HB = 126)
;deformation in upsetting; t is the time
a) Load; b) Deformation
,lized by 1iie Milks
' METHODS FOR FORMING HEADS-
The -upsettiiig7,of parts 1.t5ed for
-
fastehing' or forA
gether 101:performed moSt
-
-,Other6iiartit
br_..horisOn
cold-uimettineautomatiC:presissi
The forming ;41*heSdi, of%thiie:
parts (heading) mak be effected In t
,?.-
matrix, in the plunger and siaH1ltan.ouely_
_
in both halves ofAhildiS-(16 a;AS).
The working speed of the plunger at
the beginning of the upset is Twork =
= 0.14 1.4 m/sec. The speed of &traria-
Ition v't - 100 equals .1300-20000%/sec
'.(see Table 42), where e is the rate of .
period of deformation, in seconds.
THE PRECISION AND CLEANLIti MSS OF STAMPED SURFACE
' Cold. volume stamping and upsetting b/y cold upsetting automatic -presses !lad
by crankthrow (coining) presses will produce parts with a precision along -the axis
equal to 0.03 - 0.05 asn.
The precision in the plane perpendicular to the 'movement of theplun' ger de-
eponds on the precision with which the; --dial- are made, how correctly is the plunger -,
. ,
1
314
Declassified in Part - Sanitized Copy Approved for Release 2013/04/16: CIA-RDP81-01043R001900100003-3
Declassified in Part - Sanitized Copy Approved for Release 2013/04/16: CIA-RDP81-01043R001900100003-3
?
_j positioned in relation to the matrix and on the ability of the die to withstand
_
1 ? .
20
?-)
? -
?
Table 41
The Values of 0T' o.. d arid NB of a Calibrated Wire in Cold Upsetting
y
Process (Data Furnished by Author)
Diameter in mm
aT 0
V kg/me
av
v kg/mm2
aT
NB average
,
ay
? cry
NB
,
Steel
6.2
37.3
41.1 :
0.91
' 109
0.38
6.2
65.5
67
0.98
137 .
0.49
7
67.6
70 1 ,
0.95
140
0.5 .
7
44.1
45.8 1
0.96
123
0.37
8.6
36.2
41.6
0.87
123
0.34
8.6
48.9
55
0.88
143
0.38
8.6
56
59.2
0.94
152
0.39
8.6
49
53.3
0.92
131
0.41
5.1
64.8
69.3
0.94
152
0.45
5.12
43.7
49.3 .
0.89
134
0.37
7 .
43.5
49.5
0.88
'134
0.37
v, Brass
5.1
_ 38.4
48.5
0.79
126
0.38
5.1
35.4
42.8
9.83
123
0 35
10.4 ,
39.2
51.8 .
0.76
143
0.36
7
36.4
44.2
0 82
92
0.48
7
42.9
50.4
0 85
_
107
0.47
Aluminum
7.9
23.05 1
34.1
0,68
_
.- ,
4 ?
To obtain a higher degree of precision, calibrating operations are used, such
reducing and volume and surface coining (Table 43).
Parts requiring threads of the 2nd and 3rd class of precision are usually made!
by a cold upset combined with reducing and, threading.
,
.-315
STAT
Declassified in Part - Sanitized Copy Approved for Release 2013/04/16: CIA-RDP81-01043R001900100003-3
Declassified in Part - Sanitized Copy Approved for Release 2013/04/16: CIA-RDP81-01043R001900100003-3
0
1.)
? ". ?
34
36
3
A t:
4 .......
-- Table 42 ?
Speed of Plunger at the Beginning of Deformation and Rate of Deformation
Types of Automatic Presses
Minimum and ,
Maximum Dimen-,
sions of the
Automats in mm
-
Assumed
Value
h
D
d
.
Angle of.
Crank
Position
at the
Beginning
of Stamp-
ing in
Degrees
Speed
of
P1::::r1cv
is mtsec
.
Rate of
rilOrr:-in
%/sec
? .
.
Single-strike, cold
' With a single
piece matrix
.
0 3 - in
.
.
2
?
.
42-45
'
0.25-0.4
,
4350-1800
With a separ-
ating matrix
-
0 4 5 - 60.7-0
8
,
9000.6000upsetting
.
I
Two-strike
cold upsetting
With a single
piece matrix
0 3 - 20
A
I
3
.
.
0.7-i
.
6000.1300 .
,
With a Belli.-
sting matrix
ri 6 - 25
0.75-1 3
000-1300
Nail forming
With a uni-
versal type
matrix
0 6 - 20
1
5
90
1.25-1 4
,
7800-2300
With hori-
zontally
positioned
squeezing
and
cutting
matrixes
01 2 - 4 5
,
0.5-0.9
20,000-12,000
,
.
Cutting (may
possibly be used
for repeated
stamping oper-
tions
With a
crank-
lever
drive for
the
slide
block
0 10 - 20
,
1
.
I
-
-
0
.
n 5-0 65
?
.
1
. .
Nut stamping
,
Multi-
operational
012
.
,
I
.
,
-
.
_
-20
.
.
?
"
0. 14
.
.
.
: .
-
.
.
5
5.3 I
?H SA
-
----,--- :STA
? _7 ;
Declassified in Part - Sanitized Copy Approved for Release 2013/04/16: CIA-RDP81-01043R001900100003-3
Declassified in Part - Sanitized Copy Approved for Release 2013/04/16: CIA-RDP81-01043R001900100003-3
k
1
ing the deformation, by the properties of the deformed metal, by the shape and
1
t -
, . .
FORCE REQUIRED FOR.COLD UPSETTING__
The force required for cold upsetting is determined by the conditions affeotm-
3L'
,
C
?
_
Fig.183
dimensions of the stampings and also by the dome ,of Precision and cleanliness of
the surfaces.
The, specific pressures required to effect the shaping of steel are assumed to
- be as follows:
Operation
- Specific Pressure
in kg/2
-
Thmiet of heads (heading) of r
s-x
shape
317
150-160
STAT
S')
Declassified in Part - Sanitized Copy Approved for Release 2013/04/16: CIA-RDP81-01043R001900100003-3
Declassified in Part - Sanitized Copy Approved for Release 2013/04/16: CIA-RDP81-01043R001900100003-3
Calibrating coining
Pressingout helm products
Electro Upsetting ? -
Reducing (squeesing,the rod)
1.47,4
:"A?z?
Hot volume stamping
Cold volume stamping
Stamping with electric
42_
4
46
? for a cold upist of rOund parts with, or 'without burrs
4
? '
5 P .74,7 (1 + 0.05 7-f?--) F. kg ,
'5 2-
- where a is a coefficient found in chart of Figs.184 and 185; of is :the irui re-t'
T -
Declassified in Part - Sanitized Copy Approved for Release 2013/04/16: CIA-RDP81-01043R001900100003-3 '
Declassified in Part - Sanitized Copy Approved for Release 2013/04/16: CIA-RDP81-01043R001900100003-3
? upset head in mm; F is the projected area of the stamped-out head (including thi-
burr) in
The force required for upsetting of round bodies (without producing a burr)
"lade of Grade 10-20 in MK steel is:
?
4
3
2
0
J
29
195
495
23
04
20
2,4
1.1
493
C)
5 0 7 8 0 10 11
d)
Fig.184 - Chart Showing Values of
Coefficient a in Swaging without a
Burr
a) Operating nest not filled; b) Nor-
oral authors.
nal swaging, nest fully filled; c) Cam-
In Fig.187 two curves (a and b) are
bine(' swaging, coining; d) Nueher of
drawn as an example of relation between
experiment
P ? arD2,
where coefficient = 0.5- 0.6; aT is
the minimum value of the index of the
lieit of fluidity of the material, as
,shown by GOST in kg/2; D is the diameter
of the stamped part in CK.
The value of the deforming force,
when found for a new, complex and untested
process, should be verified experimentally
;one testing machine or by a hydraulic
Press.
Values of the force required for the
upsetting of different parts is shown in
Table 44. The data was furnished by civ-
the force required for upsetting and the
sticks of the plunger S. The material upset is: a) semiround head with formation
-I of a burr; b) hexagonal nut made from Grade 15 steel.
STAT
Declassified in Part - Sanitized Copy Approved for Release 2013/04/16: CIA-RDP81-01043R001900100003-3
Declassified in Part - Sanitized Copy Approved for Release 2013/04/16: CIA-RDP81-01043R001900100003-3
0
6 6,
)
2i-
fl
^
I
,
I -;
?51.
Force Required for Cold UPsetting (Experimental Data)
No.
.
Shape of Head
Head and Rod
Dimensions
in mm
Material
i for
, Parts
Farce
required,
ia tons
?
Remarks
Source
of
Data
d
D
h
1
Cylindrical,
3 2
4 8
0 8
iSteel 10
(gr > 18)
2
'
.
:
Data by
Author
? 2
Semiround, with
burr h = 0 22 as
thick; a = 0-1 mm
wide
4.43
,
DF6 68
3 06
1
;Steel 15
kg ;' 21)
. T?
22
Work carried
out an a
DI=8 84
? 3
Semiround
4 8
6 4
3
1
Aluminum
1 5
' testing
machine
4
Semiround
4 8
7 9
4
Steel 20
kg > 21)
7.3
5
Countersunk
6
11
,
2.9
Steel 15
27.8
By cold upset-
Data by
A.N.Gled-
kikh
6
.
Countersunk
castellated
6
,
11
2 9
.
I ,
Steel 15
29.7
ting in auto-
attic press
7
Countersunk
castellated
6 4
9 5
11 9
15 8
5 5
6 1
Steel 25
0 >25)
' T ?
Steel 15
20
Tested on
cold'upeet-
?"^ a-te-
. ....c, ..
attic and
Data by
anti-=
8
Countersunk
25
9
Semiround
9 5
16 7
5 6
Steel 15
30
vertical crank
press
10
Harrel-shaped
10
16 2
7
Steel 35
25
Tasted on cold
upsetting
automatic
press
Data by
V.A.Popow
11
.
Hexagonal
10
16 2
'
7
Steel 35
1
44
12
Semiround with
square under
head
10
21 34
4 8
Steel 35
(a >30)
:T?
100
.
.
Side of =part
In ma; height
of square
4.8 ma
13
Semiround with
square under-
head
16
34
.
? ,
8 6
Steel 35
,
,
,
200
Side of square-
16 mm; height %.
Of square ,
6.3 am
)6, J1344a 1.)7
''ull'ins-
' 7
14
Semiround with
square under-
head
19 05
40 4
,.
9 4
I
Steel 35
1
I
..
300
?
Side Of square
16 mm; height
of square
. 6.3 mm ,
15
Hexagonal nut
10
-
22
9.5
_
Steel 15
kg
I? T ? >21)
t
. ,
.
60
Tested.on-a
hydraulic test-
ingrmachine ,
Detain,
, nether
Remarks: Symbols in the Table are: d - diameter oi upset part of product; D - diameter of-1'0st
head, round without burr, or of the circle circumscribed around the square or hexagomat
shape; h - height of upset head or of praduct;,D1 - diameter of upset head with burr.
1
1
-1
_
i ?
^
?
Declassified in Part - Sanitized Copy Approved for Release 2013/04/16: CIA-RDP81-01043R001900100003-3
Declassified in Part - Sanitized Copy Approved for Release 2013/04/16: CIA-RDP81-01043R001900100003-3
SELECTION OF THE NUMBER OF TRANSITORY OPERATIONS REQUIRED AND
CALCULATIONS FOR CONICAL PLUNGERS
Cold upsetting of parts maybe effected in 1, 2, 3 and more transitions
(strikes). The number of strikes required depends on the configuration and dimen,-
Ot
A
#
Fig.185 - Chart Showing Values of
Coefficient a in Swaging with
Formation of a Burr hi. Thick
and s Wide (Bib1,29)
0'; Ailmm
120
100
80
60
4c
0
-
-
---; y12 ----J-
a)
45
API
20-
W
Fig.186 - Chart Showing the True
Resistance to Deformation
(Data by L.A.Shofman)
a) Steel
sions (see Table 45).
The number of transitions, or the relative acceptable length of the upset
' part d? is determined by the quality of the material and its diameter, i.e., it
is a function of the firmness of the stela from its longitudinal bend.
The maximum acceptable value of-9-- is shown in Table 46 (data by V.A.Popov
shows these values are applicable in upsetting by automatic presses).
A two-strike upsetting operation is the most widely used for a great variety
of parts used for fastening or for joining other parts together.
Products, if the length he) of their portion to be upset is less than 2.5 d,
as an exception, are upset not with one, but two strikes, if:
3.21
STAT
5
Declassified in Part - Sanitized Copy Approved for Release 2013/04/16: CIA-RDP81-01043R001900100003-3
Declassified in Part - Sanitized Copy Approved for Release 2013/04/16: CIA-RDP81-01043R001900100003-3
_
5
!
Pm
15
13,5
12
10,5
7,5
4,5
3
Pm
40
35
JO
25
20
15
tO
0
0 a)
Fig.187
i-0-1-.74-iii?.;--i-plUnger stroke
a) The ratio IL > 4.5 (ilt headhi.
h
_b)_Te head to be_upset_le to_hare .
a shape and dimensions requiring
specia.lAreatient (rivets with
semielliptical heads used in '
cases where the joints mist be
be reliebli);
c) The head upset l?
eximPla, cTlindr. 1:esl,164:dij;4
?
?
countersunk -ibiads. with i'?
:
underheads, squars. coun
heads.
When the part to col4-upiTt.
of a now and untested design; the sole
number of transitions required shOuld'be
verified eiperimentally.
Parts, especially complex: techno1og7
ically,mmarrequire four, and sometimes
five transitory operations. InMany.
cases, especially. in upsetting stool -
, parts containing more than 0.2% Carbon; ,
an intermediate annealing-and.a repeat,
A A
A
-
upset shoul4 be effected:
Parts upset with two or three
strikes and parts which.have?Undergone
annealing have their repeat upset in
'horizontal presses equipped with. bunker- 1
' type loading devices.
--STAT.322
?
Declassified in Part - Sanitized Copy Approved for Release 2013/04/16: CIA-RDP81-01043R001900100003-3
Declassified in Part - Sanitized Copy Approved for Release 2013/04/16: CIA-RDP81-01043R001900100003-3
0
?
? - ,
"C,
el
A repeat or a secondary upset makes it possible to widen considerably the
number of parts suitable for upsetting, including parts with inordinary configura-
tions and dimensions.
Table 45
NnAber of Transitions to be Selected in Upsetting Parts Having Stems
krill
tiOtaitOliessagS loillagr-
kg
-
Sample List of
Upset Parts
_
I
Remarks
,
ho
D
D
d
h?
d
1
< 2.5
< 4.5
< 2
_
2
188
Rivets, screws etc,
with semirouncounter-
e
sun or semicounter-
sunk heads
1. Upsetting in 2
und i is usually.
done iu one matrix I
(Fig 189a and b)
2
2.5 - 5
4.5-8.5
'
2 2 2
6
189
"
Stock for bolts,
rivets screws, etc
with cylindrical heaas,
or heads with square
anderheads
2. Preparatm fcconical)
plunger 2 (Fig 189a)
and intermediate (in 3-
strike operation) mid
finishing i(Fig 1B9b)
are set consecutively
before the strike
3
5-8
-
8.5-10
2.6 4
_
1
Screws with crosshead
cut, bolts hexagmal
inside and outside and
other complex parts
1
3. Plungers set on skis
sliding in slide block
vertically or in an
arc
4
The diameter of the base of the cone (of a conical plunger) Dk is; (specifica-
__lions of auto plant named after Stalin) (Fig.190).
24 a a
D,?tg ?2? V + ? 2 tg n;
' _where dk is the diameter of the cylindrical hole of the conical plunger or the
__smallest diameter of the stock; V is the volume of the deformed portion of the stock
4:_(from the piano of the larger base to the plane of the conets smaller base; n is the
'distance from the plane of the large base not reached by the conical plunger
n ... a - b +1.5
111 5'
..!yshare_als_the distance cram the front butt end of the matrix to the plane of the
STAT
/23
Declassified in Part - Sanitized Copy Approved for Release 2013/04/16: CIA-RDP81-01043R001900100003-3
Declassified in Part - Sanitized Copy Approved for Release 2013/04/16: CIA-RDP81-01043R001900100003-3
?
0.
n.
;large base; b is thedistance from the front butt end of the finishing plunger to 1
%
. I
?the front butt end of the matrix.(this_may_be_taken_as _a a"...b 1 _JUL a _18.1
,
:the plunger cone angle; The optimum angle of the cone for the first upset operationi
__;is equal to 6? ? 15/, for the second upset, (with a 3-strike upset) is 12P ? 15/.
b)
Fig.188 - Method of Fig.189 - Method of
Upsetting in One Op- Upsetting in TwoiSteps
oration a - End of let sep
a - Start of opera- (upsetting of head)
tion; b - End of b - End of 2nd step
operation
Fig.190 - Longitudinal Section
of a Conical Plunger
1 - Conical plunger; 2 - Thrust I
pin; 3 - Matrix; 4 - Finishing
plunger
a)Aaanie of the base
With a . 60 pk (1.2 - 1.3) dk;-mith a 12? pk - (1.5 - 1.7)d.
Equations to determine Dk without calculating the volume V are given in
HTable 47 (data by ZIS).
UPSETTING OPERATIONS WITH MATRIXES
I .
The type of matrix to be chosen for !upsetting depends upon the length of the
5--i stem of the upset part, on the nature of the work and on the quality
111
Amk54:-.1.the-finished-product-(TableJ4)....
561______Sinitle-Pisae-Tyme_of Matrixes foi_UPsettinc.(Fig.191)...__A_wire_-
required for 1
or_aLro4STAT.?.:
?
Declassified in Part - Sanitized Copy Approved for Release 2013/04/16: CIA-RDP81-01043R001900100003-3
Declassified in Part - Sanitized Copy Approved for Release 2013/04/16: CIA-RDP81-01043R001900100003-3
0 -
is fed.periodicaly by rotating channeled rollers (2) through i
l the holeof the cutting
matrix (3) until the wire or the rod reaches thrust stop (4). The forward movement
5
?
Table 46
Acceptable Values of h?
Diameter of Stock
in mm
Upset Material
Steel 1}Grode 10
Brass Ji
ItirioRrade 35
3-7
7.1-10.5
10.6-16.5
,
1.7
2.3
2.5
2
2.45
2.65 ?
of the cutter (5) cuts off a piece which, by means of a special holding device (6)
is transferred to the line of upsetting.
Table 47
.1
4.????????
DK: -137-6tg ENS + 4-2 tg 4 a:
with a .60 Dr -IV-0.314D% 4- giag ?0,1a
D -11Y- 6 tgi Dsh 0,4AW d3N ?2tg -42L n;
froth A> 111d ic H a. 6?
Dia*. 0,314D2h + 0,4441K+ d _ 0,1 n
* pia is the diameter of the base of the plunger cone in a 2?strike upsetting.
a) Sketch of part; b) Equations
When the plunger (7) is moving towards the matrix (8) the out?off piece is '
first rushed in the hole of the matrix until it is stopped by the stem of the AiAm-
STAT
325
Declassified in Part - Sanitized Copy Approved for Release 2013/04/16: CIA-RDP81-01043R001900100003-3
STAT
Declassified in Part - Sanitized Copy Approved for Release 2013/04/16: CIA-RDP81-01043R001900100003-3
?
I
20
3
34__
3,
3
Table 48
Selection of Type of Matrix for a Cold Upsetting Operation
Matrix
iype
Stem
Length
Type of Work
ior Matrix I
Quslity of
finished part
firmka
Single-piece
type
Separating
type
1 < 8d
1 > 8d
1 Stamping and _up-
setting;
z. ucing the stem
here, the mathx
consists aniy pi
:n:atrix proper<
An eye /or
the stem
1. Stamping and up[
Aetting;
2. Flattenaig, .
making ep.impres.
sums an 11121111ar
work;
3. Mtemlbending'
4 Holds stook-iiglit
to prevent part
from.moylng ,
longituainally
The ftted pert
Es swot ; no
u:as r the
The passe in the
matrix is cone-
shaped.to make the
ejecting of the
part easy.
buzr may be fgrd
tder the he at
the place of the
die separation.
? - ? ?
Stem reducing,is.mot
dome.= a-esparat4ag
matrix. In,special
automatic presses
egmipped with sepia-
ating-typeltrixas,
it is Epait e to
ypset rom, .
gm r up to
tug?a! ,Lon4E dm_ ...-k,
reuuding ay pria4g= -
ST 91 the by
.,..,
cutting .
In this ca4e, the
matrix is made with
alsea and groove; .
ced transversally.
Universal
ty
(EitEir a.
sing e-piece
ora separ-
ating type
matrix may be
placed in
the bed 9f
the matrix
1. Stamping and upl-
letting:
2 Stem reducing (if
the upsetting Was
done in a single
piece matrix
The quality of
the finished
product depends
on the tee of
ix
matr place
in the d
of the matrix
Special automatic
preases are 'leo
good for Z-sided
upsetting simultan-
eously.
During the upsetting,
the separate parts
of the matrix press
each other
To ease the ejection,
the matrix parts
move apart.
The cutting and
moving of the stock
is done in automatic
presses with single-
piece matrixes.
In this case, separ-
ating matrixes for
transverse defama-
tion are not used
326
Declassified in Part - Sanitized Copy Approved for Release 2013/04/16: CIA-RDP81-01043R001900100003-3
STAT
Declassified in Part - Sanitized Copy Approved for Release 2013/04/16: CIA-RDP81-01043R001900100003-3
:tor (9). The upsetting of the head takes place with the further movement of the
,-plunger. As the plunger returns to its place, the upset piece is pushed out by the
/. ?
1-1 ejector (9) from the matrix.
?
_'1
Fig .191
a) Line of feeding; b) Line of upset-
ting
then carried by matrix parts (4
'
:to keep it tight in place. For
and
If the matrix is of the single-
piece type, the length of the stamping
stem is determined by the position of the
ejector (9).
Upsetting with Matrixes of the
Separating Type (Fig.192). The wire or
rod (1) is fed periodically by rotating
channeled rollers(2) through the cutting
matrix (3) and through the open matrix
parts (4 and 5) until it reaches the
turning stop (6). The matrix part (4)
moving to the right cuts off a piece with
its butt surface. The cut-off piece-is
5) to the upsetting line where it is squeesed
this purpose, the clearance between the matrixes
- --as from 0.02 to 0.2 mm. The projected portion is swaged by the plunger into a head
--of required shape. Thereafter; matrixes (4 and 5), with the aid of relieving
4: !
?Spring (7), return back to the feeding line. During their return, the matrix parts
separate with the aid of roller (8) descending by means of a sloped plane (9) (or
- wedge). The stamped part is ejected frOm the open matrixes by the material itself,
- -At the next feeding cycle.
The length of the separating-type matrix determines the length of the part to
f,
IF matrixes with a hexagonal cross section are also used.
-jbe upset.
More often, the matrixes of the separating type have a square'cross section;
327
Declassified in Part - Sanitized Copy Approved for Release 2013/04/16: CIA-RDP81-01043R001900100003-3
Declassified in Part - Sanitized Copy Approved for Release 2013/04/16: CIA-RDP81-01043R001900100003-3
?
?
3
3 _
?
which
Upsetting with a Universal (Calbinod) bre of Matrix:. Universal-type matrixes i
1 single-piece matrixes divided in-half,--are-ueed-far--cold-upeetting.-----
I
The principle is the same as in up- i
setting with single-piece matrixes, the I
are
//7/
:1IX. III
II
if
47
Fig.192
a) Line of feeding; b) Line of
Upsetting
only difference being, that to ease the
ejection, the pressure between the two
halves is somewhat weaker.
Upsetting of Semispherical Heads
with Straight Notches. The upsetting is
;performed in a two-strike cold upsetting ,
automatic press with a single-piece mat- '
rix and is done in a two-step operation
(Fig.193)?
The plunger operating nest is made
by deeply impressing it in a hydraulic or;
screw-friction type of press.
The curve in Fig.194 represents the
'force necessary for deeply impressing the
nest in the plunger, made of UIOA steel.
The force required to exert the
-Pressure may be determined fraa the following equation:
-
_
Pty., T4F ,
lthere y m 3.5 - 3.75; al is the true resiiitance to the deformation of the instrumeni
-steel in kg/.s2 (maybe determined approxiiately by using the curve in Fig.186,
--iissuming the condition of maximum deformation); F is the projected area of the nest
Lder pressure in na2.
_
.J
,
The force required to axert pressure'necessary to shape the plunger nest for
Declassified in Part - Sanitized Copy Approved for Release 2013/04/16: CIA-RDP81-01043R001900100003-3
or
Declassified in Part - Sanitized Copy Approved for Release 2013/04/16: CIA-RDP81-01043R001900100003-3
?
upsetting semiround heads with straight notches is shown in Table 49.
Stamping of Screws with
Inside Hexagons. The material used is steel grade-10.
The operation is as follows: First, the
Fig.193 - Transition Steps in Upset-
ting a Semiround Head with a Straight
Notch
? 1 - Cutting off; 2 - 1st step of up.
swtting; 3 - Final upsetting of head
with notch
?
upsetting of the head is performed on a
two-strike cold upset automatic press with
a single-piece matrix (Fig.195). Next,
the upset pieces are annealed (t =
= 880 - 900?C) and, thereafter, a repeat
upset is performed in a crank-type or
automatic press, whom the inside hexa-
gonal and the final shaping of the head
is accomplished with a single strike
(Fig.196)
The head sizes of screws (the second
and third steps of the operation) and of
plungers are shown in Tables 50 and 51,
these being the specifications of the
plant "Stankonormal".
Stamping of Screws with Cross-
Shaped Nests in the Head. The shaping of screws with cross-shaped nests in the head
may be performed by the open and closed methods (Figs.197 and 198).
Table 49
Force Required for Shaping the Nest
Screw
Diameter of
Nest D in mm2
Required
Force P in m
M4
.6.5
11.2 - 14.5
M5
9.96
24.5 - 26.2
M8
12.94
35 - 44.2
,
The shaping by the open method is performed by cold upsetting in a three-
329
STAT
Declassified in Part - Sanitized Copy Approved for Release 2013/04/16: CIA-RDP81-01043R001900100003-3
Declassified in Part - Sanitized Copy Approved for Release 2013/04/16: CIA-RDP81-01043R001900100003-3
???
?
?
strike automatic press, or in a two-strike automatic with a repeat operation in a
single-strike automatic press.
With the open method, the head is upset first and the shaping follows after.
2 4 1
Fig.195
Fig.194 Fig.196
a) Length of plunger stroke
When a repeat operation is required, there should be an intermediate annealing
before the part goes to the automatic press.
The closed method of shaping is accomplished in two operations; the head is
upset in two transitory operations, the nest is shaped simultaneously with the
head during the second operation.
With thA rlARAd mwEhnel 1,?4g4 a,.8 fewer strikes required, truer shape and
330
Declassified
Declassified in Part - Sanitized Copy Approved for Release 2013/04/16: CIA-RDP81-01043R001900100003-3
Declassified in Part - Sanitized Copy Approved for Release 2013/04/16: CIA-RDP81-01043R001900100003-3
?
?
?
Table 50
Sizes of Screw Heads and of Plunger Operating Nests (see Fips.195 and 196)
b)
d, D, It, It II
a) -
M8
M10
M12
M16
C)
7.04+ 0,04
9,84+?.?4
10.67 4-0.04
14.68+0.12
11.5 1 (1.1 5,6i0,2
+ .1
17.5-0.1
23,5+0,2
7.6? 0.2
9.6?0.2
17?0,2
1.5
8
10
12,5
14.5
7.044 0,02
8.81+0,02
10,67+0,02
14.681.0,02
112
15
18
24
8?0.5
10-8-0,5
12?0.5
16 ? 0.5
5+1
6+1
8+1
10+1
8140
-0J
8+^ "
1044^ ?
19+?'3
?4-0J
a) Screw; b) Heads obtained by cold upset in automatic presses; c) Heads
after final finishing operation; d) Size S (under key)
Table 51
Dimensions of Plungers in mm
a)
D3
b)
C)
III
R
r
hi
,
1
I ,
r,
Rs
s
si
M8
M10
M12
M16
1
12_0.2
15-0,2
18_0.2
24_0.2
8-0,2
10+0.2
12.5+0.2
14.54-0.2
4
12
20
25
.1.5
1.5
6
7
0
11
10,8
12,9
14.4
16
7
5
4
3
6
8
8
10
6.3
13,3
10,3
12,3
6,2 1
8.2 1
10.2
12,2
a) Screw; b) Plunger used in the 2nd transitory operation; c) Plunger used
inside hexagonal
331
STAT
Declassified in Part - Sanitized Copy Approved for Release 2013/04/16: CIA-RDP81-01043R001900100003-3
Declassified in Part - Sanitized Copy Approved for Release 2013/04/16: CIA-RDP81-01043R001900100003-3
?
?
?
? sions are attained.
The force required to exert the necessary pressure for shaping the nest of the
p7,
7.5
3
I.5
0
Z0
I
t.5
(&)
b)
Fig.197 ? dross Shaping by the Open Method the Nest of Already
Upset Head. Curves to left: 1 ? Force required for
upsetting the cylindrical head; 2 ? Force for
shaping nest; 3 ? Ejecting force;
(a) Length of plunger stroke
head by the open method is:
where A is coefficient equal to 5-6; F is the projected area of the cross?shaped
nest in mm2; av is the true resistance to the deformation of the material in kg/mm2,
corresponding to the threshold of strengthening (see Fig.186).
Upsetting Hollow Rivets. Two methods are available for the upsetting of hol?
low rivets. To upset by the first method, special automatic presses equipped with
two matrixes, are used (Fig.199).
332
STAT
r31(
Declassified in Part - Sanitized Copy Approved for Release 2013/04/16: CIA-RDP81-01043R001900100003-3
STAT
Declassified in Part - Sanitized Copy Approved for Release 2013/04/16: CIA-RDP81-01043R001900100003-3
?
The head is upset in the first matrix (with one or two strikes).. Thereafter,
the rivet is transferred by spring actuated pins to the axial line of the second
Fig.198 ? Cross Shaping the Nest by
the Closed Method Simultaneously with
the Upsetting the Countersunk Head.
Method by A.N.Gladkikh
a) b)
s.-
_a ?FrY"Vorgi li '? 1111
"ILIM NW
3
Fig.199
a) Transition to the upsetting matrix;
b) Transition to the punching matrix;
c) Punching matrix
? matrix where the rivet stem (1) is acted upon by the punching die (3) to produce
the initial hollowness. The punching die (3) also acts as an ejector.
The final shaping of the hollow stem takes place when the rivet is pushed mit
from the punching matrix. The removal
of the rivet from the punching die is
?
5 4'j-
Fig.200
?1 effected by grippers when the upsetting
....,_.._ )
I
die (2) returns to its original position.
1
The second method of upsetting hol?
low rivets (Fig.200) i's essentially as
follows: the cylindrical piece which is
cut off from the wire is transferred to
2 "1
the line of upsetting by the first movement of the slide bar; there, the upsetting
die (1) places the rivet on the punching die (2) to make it hollow; the upsetting
of the head (formation of a cone) takes place with the further movement of the
333
Declassified in Part - Sanitized Copy Approved for Release 2013/04/16: CIA-RDP81-01043R001900100003-3
Declassified in Part - Sanitized Copy Approved for Release 2013/04/16: CIA-RDP81-01043R001900100003-3
?
?
?
Table 52
Reducing Methods
Reducing Methods
Place to
Install
the Eye
Purpose of heducing
" Squeeze" Intensity
Required f9r the
Reducing
F ? F
e _ 0 100%
Fn
CI
PUshing stock into
tationary eye
(straight method);
a - before facets
are trimmed;
b - before upset;
c - shape of eye
hole**
Moving the eye on
the immovable stock
(the reversed
method)
Matrix
b)
1 Squeezing and calibra-
ting for threading
9 Calibratiqg the smooth
portion ol bolt stem
3. stem squeezing 0 ,.,
substitute for the I--
upsetting step); the
stock is squeezed to
the Kant wtere the
head is to e shaped.
Plunger
1. Squeezing the ends of
long stock co prepare
them for threading.
2. Squeezing and calibrating
a portion of the stem
in a complex combined
operation.
In a single-step
operation, the
"squeezed inten-
sity is