Effect of forming degree in rotary hammer forging

Abstract

Abstract Rotary press forging (RPF) has been introduced in the last century. Despite its advantages, it produces defects in the forgings such as mushrooming, eccentricity, and twisting. Rotary hammer forging (RHF) is a new process invented by the author to reduce such defects. RHF is considered as a multi-axes compression forging process where the material is subjected to several repeated hammering blows to be deformed incrementally and partially, while the produced deformation zone is swept over the whole area of the workpiece. Previous works showed that the specimen geometry, the inclination angle and the rotational speed affect such defects as mushrooming effect, eccentricity and twisting angle, but they are less severe in RHF than RPF. The present work has studied the effect of the forming degree (FD) on the forgings produced by both RPF and RHF to compare between the two processes. Special set-ups have been used where a die is rotating while either a pressing head or hammering head is used to deform the specimen. Independent variable parameters were chosen such that the specimen geometry H/D = 1, the inclination angle = 4 $$^{\circ }$$ , the rotational speed N =260 rpm, number of blows per revolution in case of RHF = 1.2. The results showed that FD has its influence on the mushrooming effect, twisting angle, and eccentricity, although they are less in the case of RHF. RHF reduces the defects referred to RPF by 5 to 13% for the mushrooming effect, 0 to 33% for the eccentricity, and 70 to 80% for the twisting angle. Thus, RHF is advantageous than RPF.