FORGING

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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

OPEN DIE FORGING

CLOSED DIE FORGING (IMPRESSION
DIE)

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OPEN DIE PROCESS

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OPEN DIE PROCESS

TYPES
UPSETTING
COGGING
SOLID FORGING
PIERCING, PUNCHING AND TREPANNING
RING FORGING
COMBINED PROCESSES
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OPEN DIE PROCESS

UPSETTING

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OPEN DIE PROCESS

COGGING

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OPEN DIE PROCESS

SOLID FORGING
IS USED TO PRODUCE STOCK FOR FURTHER
FORGING OPERATIONS OR END PRODUCTS
SUCH AS BARS OR SHAFTS

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OPEN DIE PROCESS

PIERCING, PUNCHING AND TREPANNING

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OPEN DIE PROCESS

RING FORGING
Slight rotation of the ring on each press stroke
reduces the ring wall uniformly and increases
both the inside and outside diameters. The
height of the ring remains nearly constant, but
may require edging

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CLOSED DIE FORGING

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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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ADVANTAGES OF FORGING METALS

GREATER STRENGTH
REDUCTION IN WEIGHT
ABILITY TO WITHSTAND UNPREDICTABLE
LOADS
MIN OF MACHINE FINISH REQUIRED
SAVINIG IN MATERIAL
ELIMINATION OF INTERNAL DEFECTS
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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

# STEAM OR COMPRESSED AIR

# OIL SPRAYING
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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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PRODUCT DESIGN OF FORGING

CONSIDERATION FOR DESIGNING FORGED
PARTS
CONSIDERATION FOR DESIGNING
FORGING DIES
RECOMMENDED ALLOWANCES

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PRODUCT DESIGN ASPECTS

A TYPICAL PART

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PRODUCT DESIGN OF FORGING

RECOMMENDATIONS :
DRAFT
7 OUTSIDE DRAFT ANGLE
10 INSIDE DRAFT ANGLE
RADII & FILLET SHOULD BE AS LARGE
AS POSSIBLE
SHARP RADII SHOULD BE AVAILABLE
IN CASE OF SMALL DEPRESSION OR
SMALL HOLES SHOULD BE MACHINED

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PRODUCT DESIGN OF FORGING

AVOID DEEP IMPRESSIONS
THIN WALLED SECTIONS SHOULD BE AVOIDED
RAPID CHANGE OF SECTIONS SHOULD BE
AVOIDED

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

SHIELDS, GLOVES, GOOGLES Etc.

WARNING SIGNS
OPERATOR TRAINING
SAFETY SENSORS

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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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BHARAT FORGING LIMITED

PRESS SHOP
CONNECTING ROD
FRONT AXLE

DIE MANUFACTURING
MACHINES USED
DIES
LUBRICANTS

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CONNECTING ROD

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DIE FOR 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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