Forging
Forging
(OP)
What are the typical tolerances achieved, as forged, on a round, 6.5in dia. round part, when forged in 1020 steel. See drawing for final tolerances.
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RE: Forging
RE: Forging
Tks
Billy
RE: Forging
No matter what manufacturing process is used, a part of that size will need some type of secondary machining operation in order to achieve an OD tolerance of +/- 0.050", as well as achieving the desired shape on some of the diameter transitions. Cost depends a lot on the number of pieces required: for 10's of pieces, machining from bar will be lowest cost. Casting will likely be cheaper than forging under most circumstances, but will not have the same mechanical properties, fracture toughness, or surface finish. Feel free to post some additional details about the application, and I'm sure we can give you some useful feedback.
RE: Forging
RE: Forging
No requirement stated so far leads to any such conclusion.
You have not stated a tolerance on the linear dimensions controlling the axial size of the various steps. You have not stated a tolerance for concentricity or colinearity. Your drawing does not state a standard by which to interpret it.
Forgings of that general shape and size tend to be hollowed out somewhat to reduce the shipping weight, if nothing else.
My first guess at the cheapest process for producing the stated quantities and sizes is to buy circles flame-cut from thick plate by a steel distributor, edge-clamp them at the bottom to a plate, and let a CNC vertical mill gnaw on them, orbiting end mills, basically unattended, to produce the central hole and all of the reduced diameter steps, then flip the part onto a pilot in the center hole, clamp it with a stud in the pilot, and machine the OD last.
That's based on WAGs about the missing tolerances; a proper drawing could change my recommendations.
Mike Halloran
Pembroke Pines, FL, USA
RE: Forging
The bar stock approach is not a bad starting place depending on how much the CNC lathe time is priced. This is not a particularly good machining center part. A CNC lathe will remove the material faster and have a faster cycle time.