1 Organization Structure

Marketing
HR
GM
MD&CEO
Manufacturing
Quality Engineering
Finance
R&D
Sourcing
Material Services
Business Planning
Internal Audit

2 NO. OF DEPARTMENTS AND SHOPS

2.1 PRODUCTION
Cold forging shop
Machine shop
Heat treatment shop
Plating shop
Press shop
Material Testing Lab
2.1.1 Cold forging Shop
In Cold forging shop, the forming of bulk material at room temperature with no heating
of the initial slug or inter stages. The cold forming process is also volume specific and
the process uses die and punches to convert a specific slug or blank of a given volume
into a finished intricately shaped part of the exact same volume
Fig 2.1.1 Layout of cold forging shop:

There are three sections in cold forging shop:

1. Bolt maker section
In Bolt maker section production of various component carries out by Cold forging
operation like

Cam brake
2

Swing arm
Axle front wheel
Axle rear wheel
Shaft drive
Pin gear shift lever

Bolt maker machines

BM-11
BM-10
NMB-3/8
NBM-SL
BM-07
NEDSCHOFF BM-06
MAL MEDIE BM-05
NBM BM-04
CBM BM-03
NBM-01

2. Header section
In header section there are various types ofstuds are formed which is used in engines.
M8 * 205 stud acyl
M7 * 201.4 bolt stud acyl
M6 * 198 * M 7 BOLT A STUD
M7 * 193.5 BOLT A STUD
M8 * 140 BOLT STUD CYL
M10 * 244 BOLT STUD CYL
M10 * 238 BOLT STUD CYL
Fastener section
In Fastener section all the small parts such as nuts, bolts, screws etc. are formed which
is used to joint or assemble the object or piece.
Various fastener machines:
3

TKWARE 02
SASPI ROLLING
SASPI
BF 10B 3S
CHUNZU ROLLING 02
CBF COLD 64S 02
CBF 64S 01
EWM ROLLING 03
NBM

Fastener products:

Joint break arm

Notching of cam break
Shaft comp. oil pump
M5 * 10 bolt knock
M10 * 30 hex bolt
M8 * 31 flange bolt
M8 * 60 hex bolt

2.1.2 MACHINE SHOP

Introduction
Computer Numerical Control (CNC) is one in which the functions and motions of a
machine tool are controlled by means of a prepared program containing coded
alphanumeric data. CNC can control the motions of the work piece or tool, the input
parameters such as feed, depth of cut, speed, and the functions such as turning spindle
on/off, turning coolant on/off.
Section in the CNC shop:
Gear assembly section
Heat treatment section
CNC working area

Modes of operation

Automatic operation:
1. Memory operation The require program is already registered in the
CNC memory. We can just select the program and start the operations.
2. MDI operation- In the MDI mode program
Can be inputted in same format as normal programs and executed from the MDI
panel. Mostly used for simple test operation.
3. Program restart- Restarting of a program for automatic operation from an
intermediate point, a sequence no. is assigned to a block. MDI also usable as
high speed program check function.
4. Manual handled interruption- movement by this operation can be done
by overlapping it with the movement by automatic operation.
5. Sequence no. search- function is used to search for sequence no. within a
program and to start the program from the block having sequence number.

Manual operation:
Jog feed
In the jog mode, a feed axis and directionselection switch
on the machine operators panel moves the tool along the selected direction. The jog
feed rate can be adjusted with the jog feed dial rate.
Incremental feed
In the incremental (STEP) mode, pressing a feed axis and direction selection switch on
the machine operatorpanels moves the tool one step along the selected axis in the
selected direction.
Manual handled feed
In the handled mode, rotating the manual pulse generator on the machine operator
panel can move the tool.
Manual absolute on and off

When the switch is turned on, the distance the tool is moved by manual operation is
added to the current coordinates.
Part programmer structure in CNC machine

Name of the program

Selection of working plane, measuring system, units of measurement (mm or

inch).
Defining and calling work origin
Tool changing position
First position (movement in working plane) and second positioning (movement in

spindle axis) for working, spindle start and coolant on.

Third positioning for working (for mechanising, tool movement with tool radius

compensation)
Depth of cut (in feed only)
Definition of geometry preparation of profile (feeding of CNC drawing data
Return to second position, spindle stop and coolant off
Cancellation of fixed cycle, macro instruction, special command, tool radius

compensation
Return to tool change position
Movement in spindle axis and working plane.
End of part program
CNC PRODUCTS:

Kick shafts

Sprocket cam chain

Bearing races

Spacer & bushes

Fig 2.1.2 CNC Products

2.1.3 Heat treatment
In Heat treatment shop cold-formed parts are subjected to heat treatment to improve the
mechanical properties after the forming process or to eliminate undesirable properties.
Heat treatment is any one of a number of controlled heating and cooling operations
used to bring about a desired change in the physical properties of a metal. Its purpose
is to improve the structural and physical properties for some particular use or for future
work of the metal. There are five basic heat treating processes: hardening, case
hardening, annealing, normalizing, and tempering. Although each of these processes
brings about different results in metal, all of them involve three basic steps: heating,
soaking, and cooling.

Heating
Heating is the first step in a heat-treating process. Many alloys change structure when
they are heated to specific temperatures. The structure of an alloy at room temperature
can be amechanical mixture, a solid solution, or a combination solid solution and
mechanical mixture.
Soaking
Once a metal part has been heated to the temperature at which desired changes in its
structure will take place, it must remain at that temperature until the entire part has been
evenly heated
8

throughout. This is known as soaking. The more mass the part has, the longer it must
be soaked.
Cooling
After the part has been properly soaked, the third step is to cool it. Here again, the
structure may change from one chemical composition to another, it may stay the same,
or it may revert to its original form. For example, a metal that is a solid solution after
heating may stay the same during cooling, change to a mechanical mixture, or change
to a combination of the two, depending on the type of metal and the rate of cooling. All
of these changes are predictable. For that reason, many metals can be made to
conform to specific structures in order to increase
their hardness, toughness, ductility, tensile strength, and so forth.
Heat Treatment of Alloy Steel
All heat-treating operations involve the heating and cooling of metals, the common
forms of heat treatment for alloy steel are hardening, tempering, annealing, normalizing,
and case hardening.
Hardening
Alloy steel is normally hardened by heating the metalto the required temperature and
then cooling it rapidly byplunging the hot metal into a quenching medium, such as
oil,water, or brine. Most steels must be cooled rapidly to hardenthem. The hardening
process increases the hardness andstrength of metal, but also increases its brittleness.
Tempering
Steel is usually harder than necessary and too brittle for practical use after being
hardened. Severe internal stresses are set up during the rapid cooling of the metal.
Steel is tempered after being hardened to relieve the internal stresses and reduce its
brittleness. Tempering consists of heating the metal to a specified temperature and then
permitting the metal to cool.
The rate of cooling usually has no effect on the metal structure during tempering.
Therefore, the metal is usually permitted to cool in still air. Temperatures used for
9

tempering are normally much lower than the hardening temperatures. The higher the
tempering temperature used, the softer the metal becomes.
High-speed steel is one of the few metals that become harder instead of softer after it is
tempered.
Annealing
Metals are annealed to relieve internal stresses, soften them, make them more ductile,
and refine their grain structures.
Metal is annealed by heating it to a prescribed temperature, holding it at that
temperature for the required time, and then cooling it back to room temperature. The
rate at which metal is cooled from the annealing temperature varies greatly. Steel must
be cooled very slowly to produce maximum softness,
This can be done by burying the hot part in sand, ashes, or some other substance that
does not conduct heat readily (packing), or by shutting off the furnace and allowing the
furnace and part to cool together (furnace cooling).
Normalizing
Alloy steel is normalized to relieve the internal stresses produced by machining, forging,
or welding. Normalized steels are harder and stronger than annealed steels. Steel is
much tougher in the normalized condition than in any other condition. Parts that will be
subjected to impact and parts that require maximum toughness and resistance to
external stresses are usually normalized. Normalizing prior to hardening is beneficial in
obtaining the desired hardness, provided the hardening operation is performed
correctly. Low carbon steels do not usually require normalizing, but no harmful effects
result if these steels are normalized. Normalizing is achieved by heating the metal to a
specified temperature (which is higher than either the hardening or annealing
temperatures), soaking the metal until it is uniformly heated, and cooling it in still air.
Case Hardening

10

Case hardening is an ideal heat treatment for parts which require a wear resistant
surface and a tough core, such as gears, cams, cylinder sleeves, and so forth. The
most common case-hardening processes are carburizing and nitriding. During the casehardening process, low-carbon steel (either straight carbon steel or low-carbon alloy
steel) is heated to a specific temperature in presence of a material (solid, liquid, or gas)
which decomposes and deposits more carbon into the surface of a steel. Then, when
the part is cooled rapidly, the outer surface or case becomes hard, leaving the, inside of
the piece soft but very tough.
2.1.4 Metal plating and finishing

Metal finishing processes involve treatment of a metal work-piece in order to modify its
surface properties, impart a particular attribute to the surface, or produce a decoration.
Plating is a subset of such finishing operations that involves putting a coating of metal
over a base metal substrate to give various desirable properties to the object. Metal
coating is another subset of such finishing operations and involves the application of
paint or powder coating to a metal work-piece. Products from metal finishing operations
can range from structural steel to jewellery.
The reason(s) for carrying out metal finishing can include:

decoration
protection against corrosion
providing resistance to oxidation, high temperatures, or UV radiation,
imparting mechanical properties, such as resistance to fatigue, improvement of

ductile strength, or longevity,

resistance to the use of abrasives, and,
imparting electrical & thermal properties such as semi-conduction, thermal
resistance, fire resistance,etc.

The main operations that can occur in metal plating and finishing are as follows:
Cleaning: including solvent cleaning (either cold soaking or vapour phase),
aqueous cleaning, abrasive cleaning, and other types of cleaning such as
11

ultrasonic cleaning, chemical polishing and electropolishing. Cleaning is usually

carried out before the main metal finishing operation and sometimes between
operations.
Chemical and electrochemical conversion coatings: including chromating,
phosphating, anodising, and colouring, Conversion refers to the fact that these
processes involve changing or converting the surface layer to impart various
properties to the surface. These processes are usually applied before painting to
improve coating adhesion and provide corrosion protection.
Plating: electroplating of various types of metals onto metal surfaces.
Other metallic coating: including hot dipping (such as galvanising) and mechanical
plating (such as the peening process used for Dublins spire).
Organic and other non-metallic coating: covers organic and other non-metallic
coating and includes powder and liquid paints, resins and enamels. The coatings
that have been applied are subsequently dried. This can be by leaving to dry in
ambient air or assisted drying using an oven.
Stripping: used to remove previous metallic coatings from parts or to remove
coatings from articles that have to be reworked.

Equipment used for Plating

The type of equipment in use usually falls into one of the following two categories:
A series of process tanks and rinse tanks through which the work-pieces are
passed, either contained in barrels in the case of bulk small items, or hung from
racks or jigs in the case of bigger items. The majority of metallic coating
operations and conversion coatings take place in such a set-up.
Spray equipment. This is mainly used in painting and other non-metallic coating
operations. The majority of
spray equipment would be manually operated.
Automated spray equipment is sometimes used in larger
12

facilities. There are some applications involving

flow or curtain coating, dip coating, or brush
application
Various chemicals used for metal plating

Zinc
Cadmium
Zinc dichromate
Cadmium dichromate
Galvanized
Black zinc
Phosphate, black phosphate
Chrome
Nickel
Phosphate and oil

Description
Zinc
Cadmium
Zinc dichromate
Nickel
Phosphate,

Plating

Corrosion resistance level

Zinc, electroplated
Cadmium, electroplated

& other purposes

Very good
Very good, especially for

Zinc dichromate
Bright nickel, electroplated
black Manganese phosphate

wet environments
Very good to excellent
Good
Good

phosphate
Black zinc
Zinc, electroplated
Very good
Table 2.1.4 Chemicals showing resistance against corrosion:

2.1.5 Material Testing Lab

13

LAB FACILITY
INST & GAUGES CALLIBRATION
INSPECTION WITH HEIGHT GAUGE
PROFILE PROJECTOR
SURFACE PLATE
SURFACE ROUGHNESS TESTER

2.1.6 Lab Instruments

Micro Vickers hardness tester
Metallurgical microscope
Standard Rockwell hardness tester
Superficial hardness tester
Eddy current tester
Plating thickness testing gauges
Salt spray chamber
Abrasive cutter
Profile projector
Surface roughness tester
2.2 Product services
2.2.1 Tool room
2.2.2 Tool control cell
2.2.3 Production planning & control
2.2.4 Material Management & control
2.2.5 Quality Engineering
2.2.5 Maintenance

3.1 PROJECT INTRODUCTION

14

Studied everything in brief about production of various Products in Cold Forging

Shop
3.1.1 Background
Cold forging is a process in which the shape of metal is changed, by mechanical forces
only, using the ductile properties of metal. In forging, a metal work piece is
Plastically deformed by pressing, squeezing, or hammering forces at temperatures
ranging from ambient (cold
Forging) to 1,500oC (hot forging). During forging, the material should have sufficient
flow properties and work at the upper limit of the materials potential strength so as to
Fill the die cavity shape without resulting in cracks in the material. The properties of the
worked metal can be greatly enhanced by selecting the proper types and Sequence of
operations. The controlled process of deformation that takes place imparts exceptional
metallurgical soundness and mechanical properties to
The forging structural integrity, impact strength, fracture toughness, fatigue life and
uniformity.
Forging is a cost effective way to produce net-shape or near-net-shape components.
Virtually all metals can be forged. This makes an extensive range of physical and
mechanical properties available in products with the highest structural integrity. Forgings
are used in high performance, high strength, and high reliability applications where
tension,
Stress, load, and human safety are critical considerations. They are also employed in a
wide range of demanding environments, including highly corrosive, and extreme
temperatures and pressures.
1 Trends in Forging
One of the most important subjects of research and development in forging is precision
forging where high accuracy, complex and net shape components can
be produced. Cold forging has high potential to reduce manufacturing cost. If the work
material could be completely filled up into the die cavity, desired

15

accuracy of the product could be achieved, and hence high productivity could be
envisaged. However, the
complete filling up of material into the die cavity is quite difficult because of high working
pressure. The process often involves uni/multi-axial loading, large
deformation and substantial work hardening of the work material in order to achieve the
required shape. Hence,
punch and die used in cold forging often need to withstand forming stress up to 1500
N/mm2.
2 Basic Consideration (Principles)
The working pressure (loads) in forging consists of the following three principle
components.
1. Resistance for ideal deformation
2. Frictional resistance
3. Resistance for redundant work (inhomogeneous material flow)
3 Working Limits Problems
The working pressure in cold forging is so high that the sufficient depression of the work
materials to attain the desired accuracy of the products cannot be
practised within the allowance of tool strength. Therefore, the reduction of the working
pressure is the most important
problem for the improvement of the accuracy of the forged products. When complete
filling of the material into the die
is targeted, the working pressure will increase rapidly, resulting in die breakage 3.
However, if working pressure is reduced within the die strength allowance
(approx. 250 Kgf/mm2), unfilled portion will remain in the product.
4 Principle of Working Pressures
When a workpiece material is specified, the working pressure for ideal deformation is
governed by the fractional reduction in area R as shown in Figure 1.

16

Closed die forging without flash is essentially impossible to complete the filling up of the
material into the die cavitybecause becomes unity at the stroke end, and hence the
working pressure increases infinitely. Therefore, in order to
avoid a steep increase in working pressure, a flow relief portion must be prepared at
some unnecessary locations of
the contour even when the complete filling up of material is attained at necessary
contour portions.
3.1.2 Cold Forging Process
1 Cold Heading
One of the most important cold forming techanics is cold heading.
Basically it is the reshaping of unheated metal by streaking holeson a length of wire
inserted in a die. The force of the blow creates enough pressure to cause the metal to
flowoutward unrestricted into a die cavity. The h
eadoer upset portion of part generally is larger in diameter then the original blank, and
the length has been decreased. Generally speaking normal cold heading permits of
about two and half times the diameter of wire in a single blow as diagrammed in figure
1.improved techanics and minor tooling changes can increase this ratio to a limited
shown in fig. 2.1.

FIG 3.1.2(a) Cold heading

2 Trimming

17

For parts having other than round heads, an additional heading operation called
trimming is performed.a typical operation is cold forming hex-head cap screws,such as
the one shown in fig.

Fig 3.1.2(b) Trimming

3 Piercing
A final operation in the

heading sequence for making nuts

is piercing in which the

hole is punched out as a step prior

to threading.

Fig 3.1.2(c) Piercing

4 Extrusion
Extrusion, as it applies to cold heading , is the forcing of the metal into the die smaller in
diameter than that his is a the original wire stock, which increases its wire length, as
illustrated in fig. 7. This is an efficient and highly economical method for creating two or
more diameters in part being formed. Also, increasing the ratio of head-to-shank size
beyond the normal cold heading capability is possible as shown in the examples in fig. 8
and 9.

18

Fig 3.1.2(d) Extrusion

3.1.3 Cold Extrusion
Cold extrusion technology the forming of part to thr desired size and shape by moving
the metal at room temperature into a die. sufficient force is required to exceed the yield
strength of the stainless steel. Plastic deformation results which enables the metal to fill
out the die cavities to extremely close tolerances.althoughther are many cold extrusion
operation all are variation of one or more of the following:
1 Forward Extrusion
It forces the metal to flow in the same direction as the descending punch and through a
hole in the die to form a required shape and dimensions as shown in the figure. Forward
extrusion is especially useful in the production of bolts and screws, stepped, shafts, and
cyclinders.
2 Backward extrusions
It forces the metal to flow upward around the descending punch. Extrusion pressure are
generally higher and slug preparation is more critical.
3 Cold forging drawbacks

Potentially higher contact stress that may cause tool fail or excessive tool

deflection
Probable fracture due to deformation limit of cold material

19

3.1.4. DESIGN CONSIDERATION FOR COLD FORGING

1 Product Design Stage:
The engineering design team finalise the geometry, dimension, tolerance and
materialfor the final component. This is based on intended application in the desired
performance characteristic for the particular part. The service, including typical output is
a machine drawing of the final required part; which include post forging operations such
as machining, tolerance and surface finish requirements. The machine drawing of the
considered component is shown in Fig.
The first step for a production engineer to convert the machine drawing into forging part
drawing. Understanding of the function of actual part in service can be considered as a
prerequisite to efficiently handle this conversion phase. This understanding also
improves thedecision making ability for the subsequent design stages.
Once get approval from the customer on a design, move forward with the process. We
have a series of companystandards that are product specific, but we use them to create
a blueprint of the part. The same requirements and tolerances get put on the parts.
These drawings are found at every machine as the product is made. It gives the guys
on the floor a reference point so that they know exactly what were putting together.
Engineering and manufacturing work together, and by very aggressively marrying the

20

two together, weve given the customer something extra.

Fig 3.1.4 Machine Drawing Of the Component

2 Die Design Stagegn

Stage:

There are no fixed rules for designing the dies for forging. The design method adopted
is majorly dependent on the geometry of component and the processing conditions.
There are, however, a set of recommended guidelines and principles for design, which
can be adopted based on a particular situation. They are mostly empirical, and are
developed from years of practical experience. With the recent developments in virtual
process simulation using finite element method; these adopted guidelines can be further
refined to suit the exact scenario.
In case of cold forging, the design phase follows the following steps:
Determination of Parting line and Axis of Product for Manufacturing:
This step is crucial as it impacts both component quality and the method of die design.
As per the stated guidelines, the selection of parting line should be such that:
a) Deep impressions in the die are avoided to improve die life.
21

b) Die side thrust is minimised, to avoid die shift during the forging cycle.
c) Largest periphery is preferred to be placed around the parting line; so that it is easier
to force metal laterally to spread into the cavity. Putting the largest flat surface on the
parting line is the other variation of this criterion.
d) Desired grain orientation is achieved for the part to be manufactured.
In order to improve the mechanical properties of the component, it is desirable that the
grainflow orientation is perpendicular to the loading direction. This will improve the
fatigue resistance of the component. Thus, reviewing the actual application of the
component, one could select the parting line.

3 Decide the numberof stages for forging

The key terms to remember in the process are the number of dies used in the process,
as well as the number of blows. Dies are used to form the shank of the part. Conversely,
blows are the number of punches that strike the part.Tooling lined up opposite the dies
performs the punches. The cold-forming machine punches the metal in the die to mold
the part. Once we have the dies andtooling set up, were able to put material out at a
rapid rate. The key is identifying how many dies or punches are needed to perform the
operation. If you attempt to manipulate the material too much in any single die or punch,
you can negatively affect the properties of the metal. So it really is a balance to achieve
efficient manufacturing using the fewest steps, while also preserving the tensile strength
of the Metal.

Single Blow Header

22

Fig 3.1.5(a) Single Blow Header

Single-blow headers are the simplest and fastest. They can produce hundreds of pieces
per minute but are limited to minor shank extrusion and simple head shapes. In singlestroke machine, wire is sheared to length, transferred to a die , struck one blow, and
ejected. Single-blow headers are adequate when head diameters or volume is
relatively small, and the materials lends itself easily to upsetting.
Double Blow Header

Fig 3.1.5(b) Double Blow Header

When two blows are used to form the shape, the first punch starts the metal flow in a
given direction so the desired shape can be completed with the second blow, as shown
in figure. The punches oscillate between blows to one die so that a finished part is
produced with every other stroke.

Multiple-Die Machines
23

Fig 3.1.5(c) Multiple Die Machine

Where additional strokes are required for more intricate contours, multi-station or
progressive headers are used. On such machines, parts are mechanically transferred
from one die to next, and all stations work simultaneously so that a part is finished and
ejected at each stroke.

3.1.5 Thread rolling

Thread rolling consist of nothing more than passing around section of cold finished
stainless steel between two special roll-threading dies, which are mounted in a machine
in such a way as to make a material move in a through- feed manner. The surface
materials stressed beyond its yield strength, causing it to flow plastically out of place to
form the root groove sand crests. Roll threaded parts have better strength properties
and better wear resistance then similar parts that have been machined.

Fig 3.1.5(a) Thread Rolling

1 Applications Of Threads
24

The general applications of various objects having screw threads are :

fastening : screws, nut-bolts and studs having screw threads are used for

temporarily fixing one part on to another part

joining : e.g., co-axial joining of rods, tubes etc. by external and internal screw

threads at their ends or separate adapters

clamping : strongly holding an object by a threaded rod, e.g., in c-clamps, vices,

tailstock on lathe bed etc.

controlled linear movement : e.g., travel of slides (tailstock barrel, compound
slide, cross slide etc.) and work tables in milling machine, shaping machine, cnc

machine tools and so on.

transmission of motion and power : e.g., lead screws of machine tools
converting rotary motion to translation : rotation of the screw causing linear

travel of the nut, which have wide use in machine tool kinematic systems
position control in instruments : e.g., screws enabling precision movement of

the work table in microscopes etc.

precision measurement of length : e.g., the threaded spindle of micrometers

and so on.
acting as worm for obtaining slow rotation of gear or worm wheel
exerting heavy force : e.g., mechanical presses
conveying and squeezing materials : e.g., in screw conveyor, injection

moulding machine, screw pump etc.

controlled automatic feeding in mass production assembly etc.

2 Production of threads by thread rolling

In production of screw threads, compared to machining thread rolling,
is generally cold working process
provides higher strength to the threads
does not cause any material loss
does not require that high accuracy and finish of the blank
requires simpler machines and tools
applicable for threads of smaller diameter, shorter length and finer pitch
enables much faster production of small products like screws, bolts, studs etc.
25

 cannot provide that high accuracy

is applicable for relatively softer metals
is used mostly for making external screw threads
needs separate dies for different threads
Thread rolling is accomplished by shifting work material by plastic deformation,
instead of cutting or separation, with the help of a pair of dies having same
threads desired..
Different types of dies and methods are used for thread rolling which include,
Thread rolling between two flat dies
Thread rolling between a pair of circular dies
Thread rolling by sector dies

Fig 3.1.5 (b) Rolling of external threads by flat dies

Flat dies
The basic principle is schematically shown in Fig. 3.1.5(b). Flat dies; one fixed and the
other moving parallely, are used in three configurations :
Horizontal : most convenient and common
Vertical : occupies less space and facilitates cleaning and lubrication
under gravity
Inclined : derives benefit of both horizontal and vertical features

26

All the flat dies are made of hardened cold die steel and provided with linear parallel
threads like grooves of geometry as that of the desired thread.

Fig. 3.1.5(c)Principle of thread rolling by flat dies

Rolling defects and their causes

Very irregular thread with deformation of teeth

Rollers are not synchronized
Feeding is inclined respect to the axis of the rollers
Material not suitable for cold rolling
Rollers overload
Blanks surface with excessive rough

Irregular helix of thread

Rollers are not synchronized

Feeding is inclined respect to the axis of the rollers
Rollers imperfect

Threads with wrong size Outside and

Diameter of blank oversized

medium diameters both oversized

Oversized medium diameter and exact

Diameter of blank oversized. If the thread

outside diameter

of the piece is complete, the thread of the

Medium diameter oversized and

roller is not deep enough

Insufficient pressure of the rollers. If the

undersized outside diameter

thread executed is complete, the thread of

Exact medium diameter and oversized

the roller is not deep enough

Oversized diameter of blank. Thread of

outside diameter

the roller deeper than necessary

27

Exact medium diameter and undersized

Undersized diameter of blank. If the

outside diameter

thread executed is complete, the thread of

Undersized medium diameter and

the roller is not deep enough

Excessive pressure of the rollers. Thread

oversized outside diameter

Undersized medium diameter and exact

of the roller deeper than necessary

Undersized diameter of blank. Thread of

outside diameter
Outside and medium diameters both

the roller deeper than necessary

Undersized diameter of blank.

undersized

3 Advantages and disadvantages of thread rolling

This type of processing has advantages and disadvantages, so that its adoption should
be carefully considered. The advantages can be briefly listed as:
1. Speed and efficiency. The thread rolling process is undoubtedly the fastest to
execute threads in a wide range, and in fact, in some cases you can get to
production of over a thousand pieces per minute. The appropriate use of
autoloaders also allows a single operator to control multiple machines with a
considerable saving of manpower.
2. Material savings. Since there is no generation of chips, you get a slight economy
of material: lower in smaller sizes, greater in larger diameters. They are also not
ecological problems related to disposal of oil soaked chips.
3. Improvement of technological properties. Since the fibers of the material are not
cut as in conventional methods, but plastically deformed and forced to follow the
contours of the thread, there is a general improvement of all the technological
characteristics. The tensile strength, in rolled products in general, is about 10%
higher than the normal . The resistance to torsion is significantly increased, and
finally the resistance to stress, given the greater smoothness of the surfaces of
the threads, which ensures a better grip, increase of about 75%.
4. Accuracy. With the rolling of threads you can get high precision thread, suitable
for every application, but only if that the roller dies are carefully constructed and
that the blanks are properly prepared.
5. Uniformity of production. The rolling dies (or the rolling racks) are not reground
and retain their original profile until the entire band is not seriously damaged
28

(almost always with more or less extensive chipping). So the threads are
produced by thread rolling have an very uniform size if the blanks have constant
diameters and that the material always has the same characteristics.
Consequently, the dimensional control of parts produced may be limited to a small
percentage.
6. Smoothness. Browning due to compression and friction of the dies on the parts,
cause slight surface hardening and a remarkable improvement of the roughness
of the surface of the thread generated, improving its strength.
Besides these advantages, however, there are a number of disadvantages that can be
as listed:
1. High cost of the rolling dies: This factor makes it uneconomic rolling of a limited
number of pieces.
2. Parts with cavities. They are easily deformable under the pressure of the dies
and thus can not be rolled.
3. Materials with low ductility. Can not be rolled material having a coefficient of less
than 8% elongation.
4. Hard materials. Materials with a hardness exceeding 35 HRC are extremely
difficult to roll.
5. Depth-diameter ratio of the thread. When the depth of the thread is over 15% of
the diameter, the roll is very difficult because the pieces after rolling, are
distorted.
6. Preparation of the blanks. Since this procedure is based on a movement of a
definite amount of material, the accuracy of the various diameters of the thread,
depends largely on the precision with which he prepared the diameter of prerolling. It is therefore necessary that the diameter of the workpiece to be rolled is
contained in the tolerances at least equal to those required by the finished part.
So operations are required to prepare a little more complex than those required
for other methods of generation of the threads.

3.2 Raw Material selection

29

3.2.1 Introduction
Especially grades of stainless steel and other specialty alloys have been designed for
virtually every cold heading, forming, upsetting, and extruding operation. They are
necessary for the growing number of fastener components that must have the corrosion
resistance and strength to withstand harsh environments, high operating temperatures,
and great pressures, as well as requirements for special magnetic properties. For all
such components, alloy selection has also been governed by the need to reduce part
costs and secondary machining operations, thus improving productivity.

Material quality requirements

These process characteristics necessitate a proper manufacturing quality of cold

forging quality wire rod. The important features of these quality requirements are

as under:
Excellent surface quality ensuring zero defect situation so that forged

components have no defects.

Good control over quality to ensure smooth forging processes.
Good control over mechanical properties such as tensile strength and reduction

area to ensure proper cold forgeability and productivity.

Completely descaled surface to avoid forging defects such as scale pits and

resultant surface roughness.

Suitable metalurigical structure to ensure proper machinability level

3.2.2 RAW MATERIAL USED IN COLD FORGING

Alloy Steel
Boron Steel
Carbon Steel

Table 3.2.2 Chemical Composition Of Typical Cold Forging Quality Grades

1.CARBON STEELS
SR.N

GRADE

C%

SI

MN

P
30

CR

MO

PB

NI

O
1.1

AISI100

0.06

%MAX

%MAX

.10

.05

.04

.05

.04

.05

.04

.04

.03

.04

.03

6
1.2

0.10

.10

1.4

1.5

0
.

.10

0
.

AISI101

08-.

30-.6

VS1425

13
.

0
.

10-.

21-.4

VS13111

14
.07-

5
.

.13

.07

0.11

20-.4
.15

0
.30-

.05

.04

.10

60
.

.05

.04

.26-.35

.04-.09

AISI101

0.13

1.7

5
AISI101

-.18
0.15

-.20

60-.9

0
.

EN1AL

.10

08-.
1.9

30-.5

1.6

1.8

25-.4

AISI100

1.3

EN1A

15
.
07-.

85-.1
.10

.15
.80-

25-.
35
.20-.30

.06

1.20

15

2. BORON STEELS
SR
.

GRADE

C%

SI

MN

S%

P%

CR%

B%

MO
%

31

PB%

NI
%

2.1

AISI 10B21

.30

.03

.03

.10-.20

.0005-.003

.03

.03

.10-.20

.0005-.003

.03

.03

.30-.40

.0006-.003

.03

.03

.10-.20

.0006-.003

.03

.03

.20-.40

.0006-.003

.90-

.0015-.005

34-.3

60-.

015 015 1.20

8
.

90
.

34-.4

35-.

025 025 1.15

50

18-.2
2.2

AISI 15B25

3
.

1.10
.30

23-.2
2.3

8
DIN 19MNB4M .

AISI 15B41

5
.

.30

AISI 10B36M

4
.

.30

2.7

DIN 36CRB4

AISI 51B35M

9
.

1.35
-

.30

34-.4
2.6

.801.10

36-.4
2.5

.901.30

20-.2
2.4

.80-

1.65
.801.10

.10

.30

.90-

.0006-.003

.10

.15

3. ALLOY STEELS

SR
3.1

GRADE
SCM 415H

C%
.12-.18

SI%

MN

%
.

15-.

55-.9
32

S%

P%

CR% B

MO%

%
.03

.03

.851.25

PB

NI%

%
.15-.35

.25

3.2

3.3

3.4

3.5

35
.

0
.

15-.

55-.9

30
.

0
.

15-.

70-.9

30
.

0
.

10-.

45-.7

AISI 4140

35
.

0
.

15-.

45-.7

30

SCM 435

AISI 4135

EN 2

.32-.39

.33-.38

.35-.45

.38-.43

.03

.03

.80-

.15-.35

1.25
.04

.035

.80-

.301.80

.15-.25

.25

.15-.35

1.3-

1.10
.04

.035

.901.40

.04

.035

.80-

1.8
.15-.25

1.10

3.3Selection of die material

3.3.1 Introduction
Closed die forging dies are usually made from low-alloy, pre-hardened steels containing
0 35-0 50 % carbon, 1 50-5 00 % chromium, and additions of nickel, molybdenum,
tungsten, and vanadium It is difficult to heat treat die blocks safely after machining
because thermal distortion could destroy or reduce the dimensional accuracy of the
cavity Therefore, die blocks are machined after the desired hardness has been
achieved through heat treatment Die blocks containing shallow or simple cavities can be
hardened to Rc 50 However, die blocks with deep cavities, nbs, or complex design
require relatively softer, tougher materials to minimize cracking and die breakage when
the volume of parts is high and the size of the forging is limited, die inserts can be
incorporated in the die block to minimize wear Inserts are generally installed in locations
that are prone to excessive wear due to complexity of design and material flow.
Table 3.3.1 Recommended die block materials for forging various materials

33

Material

Application

Die Material

Hardness, Rc

Forged
Aluminium

Brass

Punches, die

H11,H12,H13

44-48

Die inserts

H11,H12,H13

46-50

Punches, dies

H21,H11,H13

48-52

H13,H12,H19

38-48

D2, A2 or hardweld

58-60

And inserts

Punches, dies,
Steel

And inserts

on cutting edge of
Trimmer dies

cold-rolled steel

3.3.2 Die Blocks

Production of forgings is normally earned out with a pair of die blocks on which both
cavities are machined The layout of the cavities on die blocks has to be designed to
satisfy the following conditions:
1 The die block should be the minimum size possible but strong enough to sustain the
forging loads foi the lequired production run
2 Tilting of the die block caused by off-centie loading should be minimized
34

Causes Of Die Failure

Mainly, there are three basic causes of die failure,
1 Overloading
Overloading may cause rapid wear and breakage It can be avoided by careful selection
of die steel and hardness, use of blocks of adequate size, proper application of working
pressures, proper die design to ensure correct metal flow, and proper installation of the
die in the press machine.
2 Abrasive action
Abrasive caused by the flow and spreading of hot metal in the cavity of a forging die
abrasion is particularly severe if the design of the forging is complex or in other respects
difficult to forge, if the metal being forged has a high strength Abrasion can be
eliminated or minimized by good die design, good lubricant, careful selection of die
composition and hardness, and proper heating
3 Overheating
As a die becomes hotter, its resistance to wear decreases Overheating is likely to occur
in areas of the die cavity In addition, overheating may result from continuous production.
3.3.3 Die analysis
The process used to analyze the previous die is also used for this die.The elastic-plastic
FE package (LUSAS) is used to find out whether the die would sustain the forging load
or not The same technique is used to applying the loads The force vectors produced by
the simulation package and illustrated in Fig 6 25, at the last stage of the forging
process are subjected to the inside of the die cavity The load from the press machine is
considered as a prescribed displacement acting on the surface in contact with the
machine ram towards the die cavity Due to the symmetry of the die along the vertical
axis and the similarity of the two halves of the die set, just one half of the top die is
considered A mesh system is created with 230,3-node elements connected together
35

with 149 nodes The elements m the region close to the cavity are made finer and
coarse elements are created in the regions away from the die cavity where the expected
stress is not large Irregular type of meshing is selected from MYSTRO options, because
it is more flexible for complex shapes.

3.4 Lubricants
3.4.1 Introduction to Lubrication
Lubrication is of great importance in forging operations to reduce friction
between the die and the workpiece. Considering the importance of lubricants
in the deformation processes, it is amazing that no account of their use can
be found until relatively recent times. This can be attributed to the fact that
the composition, manufacture, and use of lubricants were - and to some
extent, still are - closely guarded secrets. Additionally, it is quite possible that
lubricants assumed a vital role only at a later stage of development of
forging as technology. Effective lubrication provides better surface finish, die
life and workability. Two of the most significant lubricant developments
occurred during World War II. The phosphate conversion coating was adopted
in Germany for severe cold deformation (such as drawing and extrusion) of
steel. These developments are in practice even today.
3.4.2 Classification of lubrication mechanisms
In forging, as in most other metal forming operations, friction modeling is
complicated by the fact that any of several different regimes of lubrication
can
exist at the billet-die interface. Lange [5] classifies the lubricating
mechanisms
as:

36

1 Dry interfaces
Under "dry" conditions, no lubricant is present at the interface and only the
oxide
layers deposited on the die and workpiece materials may act as a
"separating"
layer. In this case, friction is high, and such a situation is desirable in only a
few
selected forming operations, such as hot rolling of plates and slabs and
nonlubricated extrusion of aluminum alloys. This kind of a situation is
desirable
because it allows the rolls to get a better grip of the workpiece.

3.4.3 Characteristics of ideal lubricants

In metal forming, friction is controlled by the use of appropriate lubricants forgiven
applications. There are some attributes that are generally valid for the
majority of applications, based on an evaluation by Schey [4]. In forging, the ideal
lubricant is expected to:
Control friction - Reduce sliding friction between the dies and the forging inorder to
reduce pressure requirements, to fill the die cavity, and to control metal flow.
Separation of surfaces - Act as a parting agent and prevent local welding and
subsequent damage to the die and workpiece surfaces.
Reduced Wear - should reduce wear of die while limiting wear of workpiece material to
tolerable proportions.
Protection of old and new surfaces - should cover both old and new surfaces
generated during deformation efficiently by possessing wetting and spreading
characteristics.

37

 Adaptability to varied working conditions - Function at varying pressures, temperatures

and relative sliding velocities.
Thermal Insulation - Possess insulating properties so as to reduce heat losses from
the workpiece and to minimize temperature fluctuations on the die surface.
Rapid response - should exert its influence in a short time (order of a few
milliseconds.)
Durability of liquid film - Capable of withstanding continued or repeated encounters.
Cooling Also function as a coolant in high rate forming.
Stability - Should be unaffected by temperature, oxidation, contamination,
bacteriological attack, etc..
Reactivity - Should not be corrosive to the dies or workpiece.
Harmless residues - Should not cause unwanted physical, chemical or metallurgical
changes in the products.
Application and removal - Should be easy.
Disposal - Should be possible to reclaim some lubricant and easy to treat
effluents.
Cost - Commercially available at reasonable cost.
Handling and Safety - Non toxic, non carcinogenic, etc..
Integrated Approach - As part of the activity of technology.
Cover the die surface uniformly so that local lubricant breakdown and uneven metal
flow are prevented.
Be free of residues that would accumulate in deep impressions.

38

 Develop a balanced gas pressure to assist quick release of the forging from the die
cavity; this characteristic is particularly important in hammer forging, in which ejectors
are not used.
No single lubricant can fulfill all of the requirements listed above; therefore, a
compromise must be made for each specific application. Various types of lubricants are
used, and they can be applied by swabbing or spraying. The simplest is high flash point
oil swabbed onto the dies. Colloidal graphite suspensions in either oil or water are
frequently used. Synthetic lubricants can be employed for light forging operations. The
water-base and synthetic lubricants are extensively used primarily because of
cleanliness. In addition, no single test method can evaluate all of these characteristics
simultaneously. Therefore, various testing methods exist for evaluation of one or more
lubricant characteristic
3.4.4 Selection criteria for industrial lubricants
Some of the criterion used for industrial lubricant selection is :
Tooling: What is the die alloy? How hot will it get? How complex is the die?
Workpiece: What is its composition? What is its proper forging temperature?
Forging equipment: Die ?Punch?Type and size/capacity?
Forging sequence: Number and type of die stations? Function of each? Cycle
times?
Lubricant used: Perceived advantages? Disadvantages? Application methods
used.
Lubricants have to be chosen based on the operating temperatures, relative velocities
of workpiece and die, interface pressures, adhesion to the materials involved and the
lubricant regime under these conditions. Therefore lubrication in hot forging and cold
forging are different, the former in the regime of solid-film and the latter in the regime of
mixed-film. Hot forging involves less pressures and higher temperatures than cold
39

forging. Table shows some typical lubricants used in hot and cold forging. Schey has
described extensively different lubricants, their constituents, application, and etc.
3.4.5 Lubricants used in Microturner
The great variety of processes calls for a yet larger variety of lubricants, and their
operative mechanisms are best discussed according to workpiece temperature, starting
with the simpler cold forging mechanisms and progressing to the complexities
introduced by higher temperatures. A brief review of the different lubricant types used
and their application in the different lubrication regimes and forging processes is
presented.

1 Oil-base lubricants
Mineral oils obtained from the distillation of crude oils (or their synthetic equivalents)
provide the base for many well-established industrial lubricants. Their viscosity is
usually chosen to assure predominantly hydrodynamic lubrication at the existing
velocities, pressures, temperatures, and during plastic deformation even in cold
working, and this leads to a reduction in their viscosity, counterbalanced by the usually
exponential increase in viscosity with pressure. Above some critical pressure, oils
become solids and behave as a polymer film
would. In cold working, lubrication is mostly of the mixed-film type and additives are
almost invariably incorporated to protect against direct metal-to-metal contact at
asperities. The types of additives depend on the workpiece and die compositions and
on the severity of the operation. Different additives enable use of oil-base lubricants for
boundary and EP regimes over a wide temperature and pressure range. Natural oils,
fats, etc. offer a wide range of viscosity, relatively low solidification pressures, and
usually also contain some
free boundary agents. When their viscosity is too high, they may be deposited from a
volatile solvent as is done with lanolin in the coating of Al slugs for cold extrusion. All oils
ignite at their flash point and while the residue may lubricate, especially if the oil
40

contains additives, the resulting pollution is objectionable and has led to a diminishing
use of oil-base lubricants for hot-working processes.

3.5 Study of Machine (NBM)

3.5.1 Introduction
Boltmaker is a machine which carries cold forging operation for the production of
components like cam brakes,axle,bolts etc. the machine on which i worked is national
boltmaker 1.the mechanism of machine is cold forging which is carried out by using
die-punch of various size as per the requirement. The m/c moves with the help of
pulleys of different sizes which gives feed to the m/c and electric motor gives drive to
the pulleys. The commands to the m/c is given from the panel by the operator to run the
m/c.the panel consist of many controls like to start/stop machinec,start/stop electric
motor etc .The m/c uses raw material of minimum 12mm to 25.4mm for the production
of components. During this one week of my training m/c two components were made on
i.e cam brake and axle.
Machine Parts

taper wage
taper plate
punch block
punch
stopper
cutter
quill
die block
die
die plate
transfer
finger
finger arm
41

transfer cam
kick out
bed pin
bush
feed roll
wire stand
electric motor
oil motor
control panel

3.5.2 Products
The boltmaker 1 basically produce 3 components as follows:1. cam brake
2. front axle
3. bolt etc.

Raw Material
Raw material used for the production of these components is alloy steel material called
as warm steel wire.for different components different dia sizes are used.
1. for cam brake:- dia 15.70mm is used.
2. for axle:- dia 17.50mm is used.
3. for bolt:- dia 11.68mm is used.
Cam front brake

Fig 3.5.2 Cam Front Brake

42

Cam brakes are used in motor bikes.the cam brake rotates and pushes rollers located
on brake shoe against drum. Cam brake is produced from the warm steel wire of dia
15.70.the length of 68.50mm from the feed is cut at the cut off with the cutter and is
made to pass through four die-punch to produce final component as per requirement.
Our customer for this product is Bajaj autos, hero moto corp. etc.

Procedure Of Cam Brake

For the production of cam front brake the raw material of dia 15.70 is taken from wire
stand and with the help of feed it is send into the m/c where it comes upto quill. Quill
helps to keep the wire straight and it carries the wire upto the stopper. Stopper is set
according to the requirement. When piece comes upto the stopper, cutter cuts the wire
as per the requirement and then finger collects it from there and takes it to die #1 and
holds it till the punch #1 comes and pushes the wire into die. When the piece gets inside
the die then with the help of kick out and pushing rods the piece comes out of the die
and then finger collects it from there and take it to die #2 and holds it there till the punch
#2 comes and punches the piece into die #2 and then same procedure continues till the
piece passes through die # 4 and then pushing rod pushes the piece out of the die and
with the help of conveyer piece is collected in the bin kept under the conveyer belt.

3.5.3 Die And Punches Used

Dies and punches used for the production of cam brake are made of carbide material.
The die is put into the die case and the punch is put into the punch case. All the
punches and dies are put into die and punch block respectively. Punch case consists of
punch pin of 90mm, filler of 147mm, and pico pin of 183mm approx. Similarly die case
consists of fillers, die pin of 306mm approx. The pushing rods push these die pin to kick
the piece out of the die. The flat of cam brake is made inside the punch and the body
and teeth of cam brake are made in die. Total 4 die-punches are used to produce a front

43

cam brake. Punch #2 and punch #3 are filled with spring because flat is made in punch
in this case.

sizes of flat according to the sequence

Punch #1- 24.30mm
Punch #2- 23.20mm
Punch #3- 22.40mm
Punch #4- 21.60mm

Punch #1- 16.78mm to 16.80mm

Punch #2- 17.60mm to 17.70mm
Punch #3 17.95mm to 18.05mm
Punch #4- 18.10mm to 18.25mm

sizes of body according to sequence

Die #1- 42.0mm
Die #2- 47.90mm
Die #3- 48.50mm
Die #4- 50.00mm to 50.30mm

Fig 3.5.3 Types Of Die Used In Bolt Maker Machine:

Bolt former heading die

Hex bolt die

44

Bolt trimming die

Table 3.5.3Specifications Of Cam Brake

S. no
1
2
3
4
5
6
7
8
9

Product parameter
Total length
2nd length
Body length
Flat length
Flat length
Flat dia.
Collar dia.
Collar thickness
Body dia.

Specification
77.00mm
50.20mm/50.60mm
33.50mm/33.89mm
21.50mm/21.70mm
8.05mm/8.25mm
18.05mm/18.25mm
25.00minimum
3.70mm/4.00mm
14.50mm/14.60mm

3.5.4 Instruments And Gauges Used

1. dial gauge
2. teeth alignment gauge
45

3. collar gauge
4. micrometre
5. veneer calliper

3.5.5 Tools Used Regularly

1.
2.
3.
4.
5.
6.

Allen keys
files
spanners
ring spanners
blue paste
diamond paste

Breakdown

5th August- problem was occurring at punch #1.there was improper extrusion.
Corrective action: - toning of punch was filed using diamond paste.

6th August - problem was occurring at punch #3.punch pin was broken.
Corrective action: - new punch pin was used.

7th August: - tooling problem. Punch #2 was not holding the piece of punch #1 i.e.
punch #2 was undersize and all punch toppings were out in size.
Corrective action: - punch #2 was replaced with older punch.
Preventive action: - toolings and drawings will be provided with tolerances.

Things To Check Before Starting Of M/C

1. Die and punches should be installed properly and accurately.

46

2. Fillers and pin should be of accurate length as per our requirement.

3. Timing of fingers should be accurate.
4. Timing of kick out should be accurate otherwise it can damage the transfer.
5. Oil should be running properly.
6. Piece should come out properly from the die otherwise while moving of transfer
finger and transfer can get damaged.
7. All the bolts and nuts should be properly checked.

Axle Front (Dk-15-1008)

An axle is a central shaft for a rotating wheel or gears. Cam brakes are used in motor
bikes. axle front is produced from the warm steel wire of dia 17.50.the length of 216mm
from the feed is cut at the cut off with the cutter and is made to pass through three diepunch to produce final component as per requirement. Our customer for this product is
Bajaj autos, hero moto corp. etc.

Procedure Of Axle Front

for the production of cam front brake the raw material of dia 17.50 is taken from wire
stand and with the help of feed it is send into the m/c where it comes upto quill. Quill
helps to keep the wire straight and it carries the wire upto the stopper. Stopper is set
according to the requirement. When piece comes upto the stopper, cutter cuts the wire
as per the requirement and then finger collects it from there and takes it to die #1 and
holds it till the punch #1 comes and pushes the wire into die. When the piece gets inside
the die then with the help of kick out and pushing rods the piece comes out of the die
and then finger collects it from there and take it to die #2 and holds it there till the punch
#2 comes and punches the piece into die #2 and then same procedure continues till the
piece passes through die # 3 and then pushing rod pushes the piece out of the die and
with the help of conveyer piece is collected in the bin kept under the conveyer blet.
Die And Punches

47

dies and punches used for the production of front axle is made of carbide material.the
die is put into the die case and the punch is put into the punch case.all the punches and
dies are put into die and punch block respectively.punch case consists of punch
pin,fillers and picopin.similarly die case consists of fillers,diepin.the pushing rods push
these die pin to kick the piece out of the die. the dies and punch are solid from inside
because whole component is made in die in this case.

size of head according to the sequence

punch #1 :- 64.00mm
Punch #2:- 61.00mm
Punch #3:- 50.00mmsize of body according to the sequence
Punch #1:- 60.00mm
Punch #2:- 191.00mm
Punch #3:- 170.20mm to 170.40mm

Table 3.5.5 Specifications Of Front Axle

S.no

Product parameter

Prod/process/specification

1
2
3
4
5
6
7

Head length
Body length
Trod length
Trod dia.
Head dia.
Body dia.
Total length

50mm
170.20mm to 170.40mm
27.3mm
12.85mm to 12.89mm
21.00mm to 21.50mm
15.02mm to 15.10mm
248.70mm

Instruments

48

1. veneer calliper
2. micrometre

Tools Used Regularly

1.
2.
3.
4.
5.

Allen keys
Spanner
Ring spanner
Files
Diamond paste

Breakdown

9th September: - finger timing was out and die pin was broken.
Corrective action: - finger timing was changed and new die pin was used.
10th September: - improper extrusion .t.r.d length was not coming as per
requirement.
Corrective action: - tired die was faced and timing of kick out was changed.
Result

Precision Cold Forging technology and processes for producing near-net shape or netshape engineering component are critical for the precision engineering industry to
remain competitive in the global market place. The technological data and know-how
for utilising the three innovative processing techniques and the hydro-pneumatic
pressure control system obtained in this project will be useful for future in-house and
industrial projects. A large industrial project with Microturner is on- going in the cold
forging of components. The capability of cold forging process to manufacture small netshape parts with critical dimensions can be achieved. Parts can be produced with
reduced processing steps and eliminating secondary processes such as machining
operations. As Microturner strives to become a knowledge based economy, innovative
metal processing techniques as mentioned will spark the interest for the industry to
meet the technological challenges ahead.
At present, the information with regard to tool design, process design and process
signature are continually being utilised in carrying out the existing industrial projects. In
49

the pipeline, discussion is in- progress with other local large companies and MNCs in
Cold forging of precision components. The completed research project will be a good
foundational platform to manufacture high precision and high value-added components
to maintain a strong competitiveness environment in Microturner.

Conclusion
As an undergraduate of the Bahra University I would like to say that this training
program is an excellent opportunity for us to get to the ground level and experience the
grateful to the Bahra University for giving me this wonderful opportunity.
The main objective of the industrial training is to provide an opportunity to
undergraduates to identify, observe and practice how engineering is applicable in the
real industry. It is not only to get experience on technical practices but also to observe
management practices and to interact with fellow workers.
I is easy to work with sophisticated machines, but no with people. The only chance that
an undergraduate has to have this experience is the industrial training period. I feel I got
the maximum out of that experience. Also I learnt the way of work in an organisation,
the importance of being punctual, the importance of maximum commitment, and the
importance of team spirit.

50

The training program having three destinations was a lot more useful than saying at one
place throughout the whole six months. In my opinion, I have gained lots of knowledge
and experience needed to be successful in a great engineering challenge, as in my
opinion, Engineering is after all a Challenge, and not a job.

51