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Sinter Rotary Forging: Part One :: Total Materia Article
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Sinter Rotary Forging: Part One
Sinter rotary forging is one of te prominent sinter forming processes and uses pressed and sintered metal powder preforms as starting material. Te sinter forming technique combines te advantages associated with two well-known techniques, namely powder metallurgy and conventional forming.
Sinter rotary forging is one of te prominent sinter forming processes and uses pressed and sintered metal powder preforms as starting material. Te sinter forming technique combines te advantages associated with two well-known techniques, namely powder metallurgy and conventional forming.
During sinter rotary forging, sintered preforms are subjected to a combined rolling and pressing action between a flat bottom die platen and a swiveling upper die with a conical working face, instead of a direct pressing action between two flat platens. Te cone axis of te upper die is inclined, so that te narrow indented contact sector with te preform is parallel to te lower platen. As te upper die rotates about te cone apex, te contact zone also rotates. At te same time, te platens are pressed toward each other, so that, te preform is progressively compressed by te rolling action.
This small conical contact area generated on te flat surface of te preform during indentation, which is further swept throughout te entire preform surface during rotary phase, characterizes this technique. Te technique offers several advantages in comparison to conventional sinter forging technique and one such prominent one is appreciably low load requirement to carry out te deformation because of te relatively small area of instantaneous contact surface. This leads to high tooling life and requirement of low capacity presses resulting into reduced initial investment and maintenance cost.
Also, rotary motion substantially reduces te interfacial friction due to better metal flow in te radial direction, further reducing te deformation load. Te sinter rotary forged components find applications in various industrial and commercial fields e.g. high power semiconductor, automotive, agriculture, sports, industrial automation, oil & gas etc.
Figure 1: Simple upsetting by rotary forging
Forming of simple rings by rotary forging of preforms made from metal powder by compacting and sintering is shown in Figure 2.
Figure 2: Forming of simple rings by rotary forging of preforms
As mentioned above, te rotary forging process not only has advantages such a small force, good surface quality and low installation investment, but also easily makes complete densification owing to te large shearing deformation.
Figure 3: Examples of finished gears
1. S. Singh, A. K. Jha, S. Kumar: Analysis of Rotary Forging of Sintered Preforms Part I: Indentation Phase, Tamkang Journal of Science and Engineering, Vol. 9, No 4, p. 313-324, 2006;
2. E.R.Leheup, J.R.Moon, P.M.Standring: Production of components by rotary forging of sintered preforms, Powder Metallurgy 1983, Vol.26, No3, p.129-135;
3. G-C Wang, G-Q Zhao, Y.Jia, Y,Yang: Densification laws and properties of sintered compacts in rotary forging process, Trans. Nonferrous Met. Soc. China, Vol.10, No1, February 2000, Article ID: 1003-6326(2000)01-0084-04
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