Forging Methods for Titanium Materials

Forging is a forming process where external forces are applied to titanium metal billets (excluding sheet materials) to induce plastic deformation, altering their size, shape, and properties to manufacture mechanical parts, workpieces, tools, or blanks. Additionally, forging can be categorized based on the movement of the slider into vertical and horizontal movement (used for forging long parts, lubricating and cooling, and high-speed production of parts). The use of compensating devices can introduce motion in other directions. These different methods require varying forging forces, processes, material utilization rates, production outputs, dimensional tolerances, and lubrication and cooling methods, all of which influence the level of automation.

Forging Types Based on Billet Movement:

1. Open Die Forging (Free Forging): This involves shaping metal billets between multiple dies that do not completely enclose the material. It is used for large parts and small production runs.

2. Upsetting: A process where a billet's length is shortened while increasing its diameter, commonly used for making heads on bolts.

3. Extrusion: Billets are forced through a die to create long lengths of material with a constant cross-section.

4. Impression Die Forging (Closed Die Forging): Metal is placed in a die that contains a shaped cavity, requiring more complex machinery and producing more precise parts.

5. Flashless Forging: Similar to closed die forging but without excess material (flash), resulting in higher material utilization and less post-processing.

Each of these methods has its specific applications, advantages, and considerations regarding material usage and processing conditions.

Forging Types Based on Die Movement:

1. Roll Forging: The metal is shaped by being passed through a pair of rolls with grooves, used for long parts.

2. Orbital Forging: A forging method where the die moves in an orbital manner, beneficial for parts requiring precise and even deformation.

3. Ring Rolling: A process for creating seamless rings, used for bearings, gears, and other ring-shaped components.

4. Cross-Wedge Rolling: Used for producing preforms for other forging processes, this method shapes the metal using wedge-shaped tools.

5. Radial Forging (Swaging): The billet is forged by a series of radially acting hammers, used for reducing diameter and producing hollow components.

Material Considerations and Processing Parameters

• Materials: Primarily pure titanium and various titanium alloys, available as rods, ingots, metal powders, and liquid metals.
• Forging Ratio: The ratio of the cross-sectional area before deformation to that after deformation. Correct selection of the forging ratio, heating temperature, holding time, initial and final forging temperatures, deformation amount, and deformation speed significantly impact product quality and cost reduction.
• Billet Selection: Medium and small forgings generally use round or square bars, which have uniform grain structure, mechanical properties, accurate shapes and sizes, and good surface quality, facilitating mass production. With proper control of heating temperature and deformation conditions, excellent forgings can be produced without large deformations.
  

Improving Precision and Quality

To achieve high precision in Titanium Forging:

• Avoid Overloading at the Bottom Dead Center: Overloading can affect dimensional tolerances, shape accuracy, and die life.
• Control Speed and Die Position: These factors impact forging accuracy and die longevity.
• Maintain Slider Guide Clearance: Ensuring rigidity, adjusting the bottom dead center, and using auxiliary transmission devices help maintain precision.

By considering these factors and selecting the appropriate forging method and parameters, high-quality titanium forgings with desirable properties and minimal defects can be achieved.
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