Skip to main content
Log in

State-of-the-art of plate forging in Japan

  • Production Process
  • Published:
Production Engineering Aims and scope Submit manuscript

Abstract

The state-of-the-art of plate forging processes for forming complicated parts without cutting and finishing in Japan was reviewed. For cups having comparative large thickness and plates having complicated cross-sectional shapes, plate forging is more useful than conventional billet forging due to due to comparatively small change in shape. In plate forging, forging processes such as upsetting, extrusion and ironing are included in the sequence of conventional stamping composed of shearing, bending and deep drawing in order to control metal flow in plates. Plate forging has the advantages of higher performance, larger productivity, lower cost, etc. Plate forging processes are classified into desired functions of products, local thickening, local thinning, formability improvement and forming of gears and plates.

This is a preview of subscription content, log in via an institution to check access.

Access this article

Price excludes VAT (USA)
Tax calculation will be finalised during checkout.

Instant access to the full article PDF.

Fig. 1
Fig. 2
Fig. 3
Fig. 4
Fig. 5
Fig. 6
Fig. 7
Fig. 8
Fig. 9
Fig. 10
Fig. 11
Fig. 12
Fig. 13
Fig. 14
Fig. 15
Fig. 16
Fig. 17
Fig. 18
Fig. 19
Fig. 20
Fig. 21
Fig. 22
Fig. 23
Fig. 24
Fig. 25
Fig. 26
Fig. 27
Fig. 28
Fig. 29
Fig. 30

Similar content being viewed by others

References

  1. Nakano T (2009) Introduction of flow control forming (FCF) for sheet forging and new presses. Proceedings of the International Seminar on Precision Forging, Kyoto, pp 35–40

    Google Scholar 

  2. Merklein M, Allwood JM, Behrens BA, Brosius A, Hagenah H, Kuzman K, Mori K, Tekkaya AE, Weckenmann A (2012) Bulk forming of sheet metal. CIRP Ann Manuf Technol 61(2):725–745

    Article  Google Scholar 

  3. Salfeld V, Matthias T, Krimm R, Behrens BA (2011) Analysis of machine influence on process stability in sheet bulk metal forming. Proc CIRP 3(1):32–36

    Google Scholar 

  4. Nakano T (2001) Compound technology of sheet metal forming and cold forging. J Jpn Soc Technol Plast 42(484):388–392 (in Japanese)

    Google Scholar 

  5. Kitamura K, Terano M (2014) Determination of local properties of plastic anisotropy in thick plate by small-cube compression test for precise simulation of plate forging. CIRP Ann Manuf Technol 63(1):293–296

    Article  Google Scholar 

  6. Landkammer P, Loderer A, Krebs E, Söhngen B, Steinmann P, Hausotte T, Kersting P, Biermann D, Willner K (2015) Experimental verification of a benchmark forming simulation. Key Eng Mater 639:251–258

    Article  Google Scholar 

  7. Merklein M, Koch J, Opel S, Schneider S (2011) Fundamental investigations on the material flow at combined sheet and bulk metal forming processes. CIRP Ann Manuf Technol 60(1):283–286

    Article  Google Scholar 

  8. Suzumura T, Mine K, Hirayama I, Ishihara S (2002) An experimental study of new redrawing method utilizing axial compressive force and frictional force. In: Kiuchi M et al (eds) Proceedings of the 7th international conference on technology for plasticity (vol 2), Yokohama, pp 1093–1098

  9. Ishihara S, Mine K, Suzumura T (2003) Multi action press forming of thick sheet metal. J Jpn Soc Technol Plast 44(507):409–413 (in Japanese)

    Google Scholar 

  10. Tan JC, Abe Y, Mori K, Ebihara O, Nonaka T (2007) Increase of wall thickness around corner of multi-stage drawn cup with flange using conical punches. Key Eng Mater 340–341:761–766

    Article  Google Scholar 

  11. Abe Y, Mori K, Ito T (2014) Multi-stage stamping including thickening of corners of drawn cup. Proc Eng 81:825–830

    Article  Google Scholar 

  12. Katoh K, Kondo K, Satoh K (2002) Increase of wall thickness of drawn cup by die forging process utilizing inclined die. In: Kiuchi M et al (eds) Proceedings of the 7th international conference on technology for plasticity (vol 1) ,Yokohama, pp 103–108

  13. Nishino S, Ohya K, Yuzawa Y (2010) Plate forging technology by press forming. J Jpn Soc Technol Plast 51(594):642–646 (in Japanese)

    Article  Google Scholar 

  14. Tan JC, Mori K, Abe Y (2008) Forming of tailor blanks having local thickening for control of wall thickness of stamped products. J Mater Process Technol 202(1–3):443–449

    Article  Google Scholar 

  15. Tan JC, Abe Y, Mori K, Suzuki M (2010) Forming of tailor blanks for increase in wall thickness at corner of stamped high strength steel products, Steel Research International 81(9). Suppl Metal Forming 2010:833–836

    Google Scholar 

  16. Mori K, Abe Y, Osakada K, Hiramatsu S (2011) Plate forging of tailored blanks having local thickening for deep drawing of square cups. J Mater Process Technol 211(9):1569–1574

    Article  Google Scholar 

  17. Mori K, Nishijima S, Tan JC (2009) Two-stage cold stamping of magnesium alloy cups having small corner radius. Int J Mach Tools Manuf 49(10):767–772

    Article  Google Scholar 

  18. Mori K, Tsuji H (2007) Cold deep drawing of commercial magnesium alloy sheets. CIRP Ann Manuf Technol 56(1):285–288

    Article  Google Scholar 

  19. Merklein M, Löffler M, Schneider T (2015) Plastic flow and its control in sheet–bulk metal forming of thin-walled functional components. CIRP Ann Manuf Technol 64(1):245–248

    Article  Google Scholar 

  20. Wang ZG, Yoshikawa Y, Osakada K (2013) A new forming method of solid bosses on a cup made by deep drawing. CIRP Ann Manuf Technol 60(2):291–294

    Article  Google Scholar 

  21. Suzumura T (2010) Trends in sheet forged parts manufacturing. J Jpn Soc Technol Plast 51(594):633–637 (in Japanese)

    Article  Google Scholar 

  22. Wu HC, Altan T (2004) Process optimization in stamping—a case study for flanging a clutch hub from steel plate. J Mater Process Technol 146:8–19

    Article  Google Scholar 

  23. Hayabuchi H, Iwata D, Hori H, Mori T, Mori T (2012) 1 stroke press that makes possible inline production. J Jpn Soc Technol Plast 53(623):1036–1040 (in Japanese)

    Article  Google Scholar 

  24. Maeda A, Araki K (1996) Plate gear, Japanese patent, 9–222158, (in Japanese)

  25. Sieczkarek P, Isik K, Khalifa NB, Martins PAF, Tekkaya AE (2014) Mechanics of sheet-bulk indentation. J Mater Process Technol 214(11):2387–2394

    Article  Google Scholar 

  26. Mori K, Maeno T, Fukui Y (2011) Spline forming of ultra-high strength gear drum using resistance heating of side wall of cup. CIRP Ann Manuf Technol 60(1):299–302

    Article  Google Scholar 

  27. Mori K, Maeno T, Nakamoto S (2014) Hot spline forming of ultra-high strength steel gear drum using resistance heating. Key Eng Mater 622–623:201–206

    Article  Google Scholar 

  28. Hayashi K (2006) Tool engineering for fineblanking and sheet metal forging complex work. J Jpn Soc Technol Plast 47(546):554 (in Japanese)

    Google Scholar 

  29. Hirabayashi K (2010) High precision technology on thick metal sheets—ultra-precise sheet forging technology to contribute for eco-friendly automotive manufacturing. J Jpn Soc Technol Plast 51(594):647–651 (in Japanese)

    Article  Google Scholar 

  30. Yoon J, Jeon H, Lee J (2013) Process design of cold forging with thick plate for seat recliner parts. Mater Des 49:449–455

    Article  Google Scholar 

  31. Mori K, Maeno T, Yamada H, Matsumoto H (2015) 1-shot hot stamping of ultra-high strength steel parts consisting of resistance heating, forming, shearing and die quenching. Int J Mach Tools Manuf 89:124–131

    Article  Google Scholar 

  32. Maeno T, Osakada K, Mori K (2011) Reduction of friction in compression of plates by load pulsation. Int J Mach Tools Manuf 51(7–8):612–617

    Article  Google Scholar 

  33. Osakada K, Mori K, Altan T, Groche P (2011) Mechanical servo press technology for metal forming. CIRP Ann Manuf Technol 60(2):651–672

    Article  Google Scholar 

  34. Maeno T, Mori K, Hori A (2014) Application of load pulsation using servo press to plate forging of stainless steel. J Mater Process Technol 214(7):1379–1387

    Article  Google Scholar 

Download references

Author information

Authors and Affiliations

Authors

Corresponding author

Correspondence to K. Mori.

Rights and permissions

Reprints and permissions

About this article

Check for updates. Verify currency and authenticity via CrossMark

Cite this article

Mori, K., Nakano, T. State-of-the-art of plate forging in Japan. Prod. Eng. Res. Devel. 10, 81–91 (2016). https://doi.org/10.1007/s11740-015-0648-1

Download citation

  • Received:

  • Accepted:

  • Published:

  • Issue Date:

  • DOI: https://doi.org/10.1007/s11740-015-0648-1

Keywords

Navigation