Forging Design Allowances: upset
Forging process design allowances for closed-die, open-die, ring-rolled, upset, and precision forgings. Covers draft angles (internal and external), fillet and corner radii, web thickness, rib height-to-width ratio, machining allowances, mismatch tolerance, flash extension, straightness tolerance, and dimensional tolerances (plus/minus). Materials include carbon steel, alloy steel, stainless steel, aluminum alloys, titanium alloys, copper alloys, and nickel superalloys. Tolerance ranges span small (< 1 kg) to large (> 50 kg) parts. Data per ASM Handbook Vol 14A, FIA Design Guidelines, ASTM A788, ASTM B247, BS EN 10243, AMS 4928.
| forging process | design parameter | material | notes | unit | value max | value min | value typical |
|---|---|---|---|---|---|---|---|
| upset | dimensional_tolerance_plus_mm#carbon_steel | carbon_steel | Upset forging dimensional tolerances; shank diameter controlled by initial bar; head diameter ±0.5–1.5 mm typical. | mm | 1.5 | 0.3 | 0.6 |
| upset | draft_angle_external#carbon_steel | carbon_steel | Upset forgings (heading): lateral flash on head; smaller drafts than impression die needed since primary deformation is axial compression. | deg | 5 | 1 | 3 |
| upset | machining_allowance_mm#carbon_steel | carbon_steel | Upset forging machining allowance similar to closed-die for the headed section; shank may have tighter tolerance. | mm | 5 | 1.5 | 2.5 |
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