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CONTENTS
INTRODUCTION
FORGING PROCESSES
MATERIALS
HAMMERS
PRESSES
ADVANTAGES OF FORGING
DEFECTS IN FORGING
APPLICATION
SECONDARY OPERATIONS
PRODUCT DESIGN ASPECTS
SAFETY MEASURES
COMPANY VISIT
CONCLUSION
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INTRODUCTION
By application of heat and pressure, a metal
can be altered in shape permanently without
rupture.
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FORGING PROCESSES
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TYPES
UPSETTING
COGGING
SOLID FORGING
PIERCING, PUNCHING AND TREPANNING
RING FORGING
COMBINED PROCESSES
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SOLID FORGING
IS USED TO PRODUCE STOCK FOR FURTHER
FORGING OPERATIONS OR END PRODUCTS
SUCH AS BARS OR SHAFTS
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MATERIALS
CARBON, MICRO ALLOYED AND ALLOYED
STEELS
STAINLESS STEEL
ALUMINIUM ALLOYS
COPPER BASED ALLOYS
HEAT RESISTANT ALLOYS OF IRON, Ni, Co
TITANIUM ALLOYS
MAGNESIUM ALLOYS
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HAMMERS
BOARD HAMMERS
AIR-LIFT HAMMERS
STEAM OR AIR-POWERED HAMMERS
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PRESSES
MECHANICAL PRESSES
SCREW PRESSES
HYDRAULIC PRESSES
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GRAIN FLOW
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DEFECTS
CRACKS
TEARS
UNDERFILLING
PITTING
DENTS
LAPS
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APPLICATION
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SECONDARY OPERATIONS
HEAT TREATING
MACHINING
FINISHING OPERATIONS
REMOVAL OF OXIDE SCALES
CLEANING (PICKLING, TUMBLING,
BLAST CLANING)
SHOT PEENING
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HEAT TREATING
TO IMPROVE MECHANICAL PROPERTIES
OF FORGED COMPONENTS
UNIFORM GRAIN STRUCTURE
TO RELIEVE INTERNAL STRESSES
ALL SEVEN GROUPS OF ALLOYS CAN BE
HEAT TREATED
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MACHINING
TO ACHIEVE FORM AND FINAL
TOLERANCE
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FINISHING OPERATIONS
-REMOVAL OF OXIDE SCALES
WHY ?
DURING MACHING CUTING TOOL LIFE
REDUCES
DIE WEAR
TO FACILITATE SURFACE COATING
FINISHING OPERATIONS
-CLEANING
PICKLING
IMMERSED IN ACID SOLUTION
12% TO 15% OF CONCENTRATED
SULFURIC ACID WITH WATER
IN SOME CASES ACID SOLUTION IS
HEATED
MOSTLY FOR NON FERROUS FORGINGS
(Cu, BRASS, BRONZE, Al, MONEL)
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FINISHING OPERATIONS
-CLEANING
TUMBLING
FORGED COMPONENTS ARE ROTATED
WITH LOOSE ABRASIVES TO REMOVE
THE SCALE
CARE SHOULD BE TAKEN WHEN
FORGING HAVE SHARP EDGES AND
SHARPLY DEFINED SECTIONS
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FINISHING OPERATIONS
-CLEANING
BLAST CLEANING
SAND, GRIT OR METALLIC SHOT ARE
MIXED WITH AIR AND FORCED AGAINST
FORGINGS
USED FOR SMALL AND MEDIUM SIZE
FORGINGS
IMPROVES SURFACE FINISH
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FINISHING OPERATIONS
-SHOT PEENING
ROUND METALLIC SHOT IS THROWN IN
RELATIVELY HIGH VELOCITY
INCREASES THE FATIGUE STRENGTH
PITTING
CRANK SHAFTS, CAM SHAFT,
CONNECTING RODS, GEARS AND
SPRINGS.
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DIE:
THE PARTING LINE SHOULD BE ARRANGED IN
ONE PLANE AS NEARLY AS POSSIBLE SO THAT
EXCESS METAL OR FLASH CAN BE TRIMMED
INSERT DESIGN
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DESIGN ASPECTS
PARTING LINE SELECTION :
AVOIDANCE OF DEEP IMPRESSION
AVOIDANCE OF SIDE THRUST
FAVOURABLE GRAIN SIZE
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DESIGN ASPECTS
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SAFETY MEASURES
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COMPANY VISITED
BHARAT FORGE LIMITED, PUNE
ONE OF THE ASIAS BIGGEST
ALMOST ALL AUTOMOTIVE LEADERS ARE
THEIR CUSTOMERS
MANUFACTURING CRANK SHAFTS, FRONT
AXLE, REAR AXLE, CONNECTING RODS,
CAM SHAFTS etc
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DIE MANUFACTURING
MACHINES USED
DIES
LUBRICANTS
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CONNECTING ROD
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FORGING DIE
MATERIAL
HARDNESS
LIFE
MANUFACTURING
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DIE MANUFACTURING
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DIE MANUFACTURING
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DIE MANUFACTURING
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DIE MANUFACTURING
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DIE MANUFACTURING
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DIE MANUFACTURING
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CONCLUSION
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THANK YOU
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