An exercise in cold ironing as the post-forging operation for net-shape manufacture

Cold ironing of thick-walled cylinders has been examined to study the process as a potential post-forging operation for net-shape manufacture practice. Steel test-pieces with different sizes were reduced in diameter in a single or double ironing process. The surface finish and geometry were examined for various initial and process conditions. The use of lubricant in the process was also studied, with emphasis on the surface topography. Finally the application of the cold ironing process to case hardening test-pieces was investigated. It was concluded that ironing had beneficial effects upon the final dimensions and surface finish of the test-pieces. Finite element modelling of the process has also been carried out to analyse the process, the FE model being validated for further parametric study.