Module No

Title

Status

1

Cold deformation of metals.

Available

2

Hot deformation of metals.

Available

3

Estimation of forging loads.

Available

4

Calculation of forging energy.

Available

5

Load estimation in closed die forging.

Available

6

Load and energy estimation in hot and warm forward extrusion.

Available

7

Load and energy estimation in hot and warm backward extrusion.

Available

8

Miscellaneous load, energy and power estimations.
 

Available

Section 2 - Forging Plant

Module No

Title

Status

9

Forging plant, types and characteristics.

Available

10

Forging plant: Hammers.

Available

11

Forging plant: Screw presses.

Available

12

Forging presses.

Available

13

Horizontal upsetting machines.

Available

14

Electrical upsetters.

Planned

15

Trimming or clipping presses.

Available

16

The hammer press.

Planned

17

Orbital forging presses.

Available

18

Automated horizontal presses.

Planned

19

Hydraulic presses.

Planned

20

Multiram presses.

Planned

21

Reducer rolls.

Planned

22

Transverse rolling machines.

Planned

23

Clearspace hammers.

Available

24

Key driving machines.

Planned

25

HERF machines.

Planned

26

Miscellaneous forging plant.

Planned

27

Comparison of forging plant.

Planned

28

Mechanisation of forging plant.
 

Planned

Section 3 - Hammer and press die design

Module No

Title

Status

29

Forging design.

Available

30

Die design principles.

Available

31

Selection of bar size in forging.

Available

32

Parting lines.

Available

33

Rib and web design.

Available

34

Corner and fillet radii.

Available

35

Preforming.

Available

36a

Metal flow in fullering and rolling.

Available

36b

Empirical methods of fuller design.

Available

36c

Double fuller design.

Available

37

Design of rolling tools.

Available

38

Design of bending tools.

Available

39

Mould design.

Available

40

Flash and gutter design.

Available

41

Die and insert dowels.

Available

42

Die clash and dovetail areas.

Available

43a

Die layout and die block size.

Available

43b

Swage tool design.

Available

43c

Cut-off design.

Available

43d

Die inserts.

Available

43e

Shrink fitting.

Available

43f

Sprue and gate design.

Available

43g

Aids to die setting and maintaining die set.

Available

43h

Sheared preform design.

Available

43j

Development of die design.

Available

43k

Improving material utilisation.
 

Available

Section 4 - Upsetter die design

Module No

Title

Status

44

Principles of horizontal upsetting.

Available

45

Simple cone design.

Available

46

Simple cone designs examples.

Available

47

Complex cone design.

Available

48

Tube upsetting.

Available

49

Special design methods.

Planned

49a

Miscellaneous upsetter design features.

Available

49b

Piercing tools.
 

Planned

Section 5 - Forging defects

Module No

Title

Status

50

Billet defects.

Available

51

Shearing defects.

Available

52

Heating defects.

Available

53

Forging and clipping defects.
 

Available

Section 6 - Design of clipping, piercing and setting tools

Module No

Title

Status

60 >

Planned

Section 7 - Forging dies and tools

Module No

Title

Status

70

Modules of die failure.

Available

71

Shearing defects.

Available

72

Heating defects.

Available

74

Forging and clipping defects.
 

Available

Section 8 - Quality control A

Module No

Title

Status

80

Conventional quality control.

In preparation

81

BS 5750 - ISO 9000.

In preparation

Section 9 - Welding of dies and tools

Module No

Title

Status

90

Welding in the drop forge.
 

Available

Section 10 - Area and volume calculation

Module No

Title

Status

100

Area and volume calculation.
 

Available

Section 11 - Reducer rolling

Module No

Title

Status

110

Reducer rolling principles.

Available

111

Theory of reducer rolling.

Available

112

Calculation of side spread.

Available

113

Preparation for reducer roll design.

Available

114

The Eumuco method of roll design.

Available

115

A graphical method of reducer roll.

Available

116

Design based on the Eumuco design.

Available

117

Determination of pass lengths.

Available

118

Example of reducer roll design using the Eumuco based graphical method.

Available

119

National Machinery presentation of reducer roll design rules  tabular method.

Available

120

National Machinery presentation of reducer roll design rules monogram method.

Available

121

A graphical method of reducer roll design based on the National Machinery design rules.

Available

122

Design example using the National Machinery graphical design method.

Available

123

Preparing drawings for reducer rolls.

Available

124

Practical considerations in reducer rolling.
 

Available

Section 13 - Quality control B

Module No

Title

Status

130

Principles of statistical process control (SPC).

Available

131

Establishing machine and process capability.

Available

132

Numerical assessment of capability.

Available

133

Use of control charts.

Available

134

Methods of quality improvement.
 

Available

Section 14 - Shearing

Module No

Title

Status

140

Shearing of billets.

Available

141

Shearing practice.

Available

142

Conventional shear blade design and material selection.

Available

143

Special shear blade designs.

Available

144

Shearing defects.

Available

145

Preheating of billets for forging.
 

Available

Future modules not yet started

A

Forging costing and estimating.

B

Forging materials.

C

Heat treatment for drop forgers.

D

Non-destructive testing of forgings.

E

Precision forging.

F

Cold forging.
 

Comments

As is noted, some the modules are planned or in preparation. When new or revised modules are received they will be compiled and distributed to members.
Dr Thomas has advised that modules that are currently planned or in preparation can be prioritised if there is a member demand.
 

For additional information please contact AFG secretary, JK Anderson .