TABLE OF CONTENTS

TITLE

PAGE No.

BONAFIDE CERTIFICATE
ABSTRACT
ACKNOWLEDGEMENTS
LIST OF SYMBOLS AND ABBREVATIONS

INTRODUCTION

Engine Valves and its function

Types of Engine Valve and

Valve materials

METAL FORMING PROCESS

Metal working and its types

Types of forging process

Impact forging

Drop forging

Upset forging

Engine valve manufacturing process

15

TITLE

PAGE No.

LITERATURE SURVEY

ENGINE VALVE OUTLINE

20

UPSETTING PROCESS AND

ITS PARAMETRIC STUDY ON ENGINE VALVES
Objective of the project

21

Project plan

24

Data collected

26

Correlation of datas

32

Data Sheetn

39

Advantages

41

CONCLUTION

42

REFERENCES

INTRODUCTION

ENGINE VALVES

An engine valve is a very important part of your engine running. It is in the head
which is just over the block and pistons. There are exhaust and intake valves. The
camshaft triggers the valves to go up at certain point to allow air and fuel in for
intake and allow waste to get out through exhaust. they return down with a spring
and seal up the combustion chamber give you the compression needed for the
engine to run and the fuel to ignite and drive the pistons. timing is everything when
it comes to valves or basically anything in an engine.
Engine valves are located in the cylinder head. The main function of the engine
valves is to let air in and out of the cylinders. That air is used to help ignite the fuel
which will drive the pistons up and down.

There are two types of engine valves; intake and exhaust valves.
The intake valves of course let air in, and the exhaust valves let exhaust air out.
The more air you can move air in and out of the engine the more efficient, and
therefore power the engine will have. The Inlet valves are typically made of
SUH-11,SUH-38 (Martensite materials) and the Exhaust valves are made of
21-4N, 23-8N(Austenite materials) for many performance applications. This is
why the engine valve plays a pretty critical role in an engines performance.
3

TYPES OF VALVES
* Monometallic Valves
Valve built of a single material that
forms the stem and the head. They
possess excellent mechanical
properties although they are not so
good at corrosion. Chromium-nickelmanganese- tungsten stainless steels
are used for exhaust valves.

*Bimetal Valves
Valve made by joining together two
different valve materials by friction
wielding wherein high hot hardness
alloy steel (austenitic steel) is used at
the head and the stem made from a
upright mechanical properties steel
(martensitic
steel). In this way a better usage of the properties of each material is achieved, high
temperature corrosion resistance in the austenitic stainless steels of the head, and
high tensile strength and abrasive wear resistance in the martensitic stainless steel
of the stem. This technique is used in medium to high stressed exhaust valves and
in high stressed intake valves.

*Projection Welded tip Valve

A small piece of martensitic steel is
welded on the stem end when the
entire valve is manufactured in
stainless steel (non-quenchable). This
is done to increase the impact and wear
resistance of the stem end. Then, this
4

tip is
quenched to improve their mechanical properties.

*Stellite Welded Valve (Special alloys

welded onto the seat)
To improve the corrosion and high temperature
wear resistance, mainly in exhaust valves, a cord
of special material is placed onto the valve seat.
Valves made by using deposit of stellite
to get high hot hardness at the seat. The special material is generally a cobalt base
alloy (called Stellite), although it can also be iron or nickel base.

*Chrome Plate Valve

Through an electromechanical process a layer of
hard chromium is stored over the stem. The
thickness of this layer generally will depend on
the level of the piece stress. The main function of
the chromium layer is to reduce the friction
between the stem and the valve guide, and to store among its micro-cracks, small
amounts of lubricating oil. All this results in better operating conditions increasing.
Therefore the useful life of the valve guide and stem

COMMON VALVE MATERIALS

These materials are selected to meet specific engine requirements. The definition
of stainless steel is generally accepted to be a steel alloy containing at least 10%
chromium in its composition. As can be seen below, Sil 1 approaches this level
while maintaining many of the favorable characteristics and lower costs associated
with the inexpensive carbon steel alloys. Sil XB, 422, 21-2N, and 21-4N are true
stainless alloys.
1541: Carbon steel with added manganese for improved corrosion resistance.
8440: Medium to heavy duty steel alloy with a higher chromium content to
enhance high temperature
Strength.
Sil 1: Heavy duty steel alloy with 8.5% chromium content for excellent high
5

temperature performance.
Used for many factory high performances intake valves.

Sil XB: A ferritic stainless steel alloy, with 20% chromium content and 1.3%
nickel. Used in heavy duty intake valves.

422: A stainless steel alloy specified for high performance intake valve usage. This
specialty type of stainless is designed with the temperature ranges and
characteristics of intake valves usage in mind, and is different from the more
common exhaust valve stainless materials. Our 422 stainless valves are easily
equal to any of the severe use valves on the market.

Ti-6: Titanium is a lightweight, nonferrous material used in high RPM racing

applications. It is 40% lighter than steel and maintains its strength at high
temperatures. Normally used for the larger intake valves, although there are limited
uses for titanium exhaust valves as well.

21-2N: Austenitic stainless steel with 21% chromium and 25% Nickel. As the most
popular exhaust valve material, it has excellent performance characteristics at
elevated temperatures. With additional heat treating and manufacturing processes,
this material can be upgraded to become the ultimate choice for exhaust usage.
With different processes, it makes for a good quality, inexpensive intake valve as
well.

21-4N: An Austenitic stainless steel similar to 21-2N, except for a greater nickel
content (4%), used as an alternate to 21-2N.

METAL FORMING PROCESS

Metalworking
Metalworking is the process of working with metals to create individual parts,
assemblies, or large scale structures. The term covers a wide range of work from
large ships and bridges to precise engine parts and delicate jewelry. It therefore
includes a correspondingly wide range of skills, processes, and tools.
Metalworking is a science, art, hobby, industry and trade. Its historical roots span
cultures, civilizations, and millennia. Metalworking has evolved from the
discovery of smelting various ores, producing malleable and ductile metal useful
for tools and adornments. Modern metalworking processes, though diverse and
specialized, can be categorized as forming, cutting, or joining processes. Today's
machine shop includes a number of machine tools capable of creating a precise,
useful workpiece.

TYPES OF METAL FORMING:

Rolling
Forging
Extrusion
Tube and Wire drawing
Deep drawing

TYPES OF FORGING OPERATION

Forging was the first of the indirect compression-type process and it is probably
the oldest method of metal forming.
It involves the application of a compressive stress, which exceeds the flow stress of
the metal. The stress can either be applied quickly or slowly. The process can be
7

carried out hot or cold, choice of temperature being decided by such factors as
whether ease and cheapness of deformation, production of certain mechanical
properties or surface finish is the overriding factor.
There are two kinds of forging process:
1. Impact forging
2. Press forging.
In the former, the load is applied by impact, and deformation takes place over a
very short time.
Press forging, on the other hand, involves the gradual build up of pressure to cause
the metal to yield. The time of application is relatively long.
Over 90% of forging processes are hot.

1. Impact forging
Impact forging can be further subdivided into three types:

Smith forging,
Drop forging,
Upset forging.

Smith Forging

This is undoubtedly the oldest type of forging, but it is now relatively uncommon.
The impact force for deformation is applied manually by the blacksmith by means
of a hammer. The piece of metal is heated in a forge and when at the proper
temperature is placed on an anvil. This is a heavy mass of steel with a flat top, a
horn which is curved for producing different curvatures, and a square hole in the
top to accommodate various anvil fittings. While being hammered the metal is held
with suitable tongs.

Formers are sometimes used; these have handles and are held onto the work piece
by the smith while the other end is struck with a sledgehammer by a helper.
The surfaces of the formers have different shapes and are used to impart these
shapes to the forgings.
One type of former, called fuller, has a well-rounded chisel-shaped edge and is
used to draw out or extend the work piece. A fuller concentrates the blow and
causes the metal to lengthen much more rapidly than can be done by using a flat
hammer surface. Fullers are also made as anvil fittings so that the metal is drawn
out using both a top and bottom fuller. Fittings of various shapes can be placed in
the square hole in the anvil.
The working chisels are used for cutting the metal, punches and a block having
proper-sized holes are used for punching out holes. Welding can be done by
shaping the surfaces to be joined, heating the two pieces then adding a flux to the
surfaces to remove scale and impurities. The two pieces are then hammered
together producing welding.
The easiest metals to forge are the low and medium carbon steels and most smith
forgings are made of these metals. The high carbon and alloy steels are more
difficult to forge and require great care.

Drop Forging

This is the modern equivalent of smith forging where the limited force of the
blacksmith has been replaced by the mechanical or steam hammer.
The process can be carried out by open forging where the hammer is replaced by a
tup and the metal is manipulated manually on an anvil.
The quality of the products depends very much on the skill of the forger.

(i)

Open forging

Open forging is used extensively for the cogging process where the work piece is
reduced in size by repeated blows as the metal gradually passes under the forge.
9

The cogging of a prismatic bar can be used to assess the parameters involved and
how they are controlled.
The objective is to reduce the thickness of the work piece in a stepwise sequence
from end to end. Several passes may be required to complete the work and edging
is usually carried out to control the width. The reduction in thickness is
accompanied by elongation and spreading. The relative amounts of elongation and
spread cannot be calculated theoretically but they have been determined
experimentally for mild steel.
(ii)

Die drop forging

Closed-die drop forging is widely used and the tup and anvil are replaced by dies.
Matching dies fit into the anvil and the tup. The dies have a series of grooves and
depressions cut into them and the work piece is passed in sequence through a
shaping series.
These stations have names such as fullering, blocking, edging, bending and cut off.
Where several stages are involved, care must be taken to ensure that the metal does
not become excessively chilled before the last station is reached. To ensure that the
die cavity is completely filled the volume of the starting billet is greater than that
of the final forging.
The excess metal appears as a "flash" at each stage, this is a thin fin around the
perimeter of the forging at the parting line. This flash is cut away in a further press
operation generally at a high temperature. The weight of flash may be a small
percentage of the total weight for forgings of simple shapes but may exceed the
weight of the actual forging for those of complex shape.
Each size and shape of forging will thus require a separate set of forging and
trimming dies. The production tolerance for the initial metal must involve excess,
e.g. ~10 mm. The over-tolerance metal is accommodated by a gutter around the die
cavity which allows the formation of the fin referred to earlier.

Upset Forging

10

This process was developed originally to gather, or upset metal to form heads on
bolts. Today the purpose of this machine has been broadened to include a wide
variety of forgings.
It is essentially a double-acting press with horizontal motions rather than vertical.
The forging machine has two actions. In the first, a movable die travels
horizontally towards a similar stationary die. These two dies have semi-circular
horizontal grooves, which grip the bars. A bar heated at the end is inserted between
the movable and stationary die. While thus held, the end of the bar is upset or
pressed into the die cavity by a heading tool mounted on a ram, which moves
towards the front of the machine.
If hexagon heads are desired, a heading tool will upset some of the metal into a
hexagon-shaped die cavity. For more complex forgings, as many as six different
dies and heading tools may be used in turn in a similar manner to the different
stations in die drop forging.

2. Press Forging
11

Whereas impact forging usually involves a mechanical press, press forging, on the
other hand, requires hydraulic power.
The largest forgings are invariably produced on large hydraulic presses. These
have vertically moving rams, which move down slowly under considerable
pressure.
A typical press forge would be capable of loads of the order of 6000 to 10000 tons.
Forgings up to 100 tons weight can be handled easily in this forge and the highestquality products are manufactured by this technique.
DETAILS OF UPSETTING PROCESS
Upset forging increases the diameter of the workpiece by compressing its length.
Based on number of pieces produced this is the most widely used forging process.
A few examples of common parts produced using the upset forging process are
engine valves, couplings, bolts, screws, and other fasteners.
Upset forging is usually done in special high speed machines called crank
presses, but upsetting can also be done in a vertical crank press or a hydraulic
press. The machines are usually set up to work in the horizontal plane, to
facilitate the quick exchange of workpieces from one station to the next.
The initial workpiece is usually wire or rod, but some machines can accept bars up
to 25 cm (9.8 in) in diameter and a capacity of over 1000 tons. The standard
upsetting machine employs split dies that contain multiple cavities. The dies open
enough to allow the workpiece to move from one cavity to the next; the dies then
close and the heading tool, or ram, then moves longitudinally against the bar,
upsetting it into the cavity. If all of the cavities are utilized on every cycle then a
finished part will be produced with every cycle, which is why this process is ideal
for mass production.

12

Rules to be followed in Upsetting:

The following three rules must be followed when designing parts to be upset
forged :

The length of unsupported metal that can be upset in one blow without
injurious buckling should be limited to three times the diameter of the bar.
Lengths of stock greater than three times the diameter may be upset
successfully provided that the diameter of the upset is not more than 1.5
times the diameter of the stock.
In an upset requiring stock length greater than three times the diameter of the
stock, and where the diameter of the cavity is not more than 1.5 times the
diameter of the stock, the length of unsupported metal beyond the face of the
13

die must not exceed the diameter of the bar.

Upset forging increases cross-section by compressing the length, this is used in
making heads on bolts and fasteners, valves and other similar parts.
This process uses barstock which is heated at the end which is being forged. The
bar is gripped in the fixed half of a die so that the length of material being forged
projects. The forging blow is delivered by a moving die. Simple shapes are
produced in a single stage but more complicated shapes require multiple stages.
The process, if carried out cold is called cold heading.
Mainly It's the production process under which high pressure deforms plastically
metal into high strength components. It is also called hot heading process. Using
this process cross-sectional size of a bar can be increased, either at ends or at some
point along the length. Specially designed upsetting machines using closed dies are
used to control size and shape.
They can be made in various sizes. The mechanical press producing these
components operates horizontally. The dies are split up allowing material to reach
beyond the mechanical press. The forming force is supplied by a third die attached
to the header. The process when done cold is called Cold Heading.
Upsetting ratio
The upsetting ratio s sets the limits of stock dimensions in relation to the danger of
buckling during upset forging. What is known as the upsetting ratio is the ratio
of free length of stock not inserted in the die to the initial diameter of the stock
S = Upsetted length / Diameter of the raw material

14

Permissible upsetting ratio:

If the upset part is to be produced in one operation S <= 2.6
If the ratio exceeds 2.6, then there occurs a condition of buckling,

15

Advantages of Upset Forgings :

Greater Strength: As the material grain flow is oriented to the component's

shape, compared to parts machined from bar stock, upset forgings offer
greater strength.
Piercing and Trimming Operations: This contribute towards component
weight reduction and eliminate machining operations.
Economical Production: As Upset forgings require fewer operations, have
lower scrap costs, that can result in more cost efficient production

Application of Upset Forgings :

Artillery shells, cluster gear blanks, heads of bolts, valves, single and cylinders for
radial engines are examples of parts made by upset forging.

16

ENGINE VALVE MANUFACTURING PROCESS

The valve manufacturing process is carried out by the following stages,

Cutting
The Special Centre-less grounded and 100%ultrasound crack
detected round bars with H9 tolerances are cut smoothly into
pieces.
Electric Upsetting
Temperature and pressure controlled Upsetting
machines process steel bar to critical temperature to prepare for
smooth Hot Forging
Friction Welding
Magnetic and Non Magnetic Stainless Steel round bars are
welded together on Special Purpose Machines to achieve
purpose of different material behaviour on different areas of
Engine valves.

17

Forging
High precision hot forging is perfomed on Friction screw and high speed pressing
upto 400 M.Tons capacity. Forming a smooth and blend profile of engine valve.

CNC Turning
Turning on complete valve areas are performed on special
purpose CNC Turning centres, meeting close dimensional
accuracies upto 0.005mm.
Stress Relieving
Stress Relieving and Tempering operations are performed for
achieving metallurgical physical properties.

18

Stellite Welding
Seat and stem Hard facing is performed on ATA Engine
Valves at fully automatic Special stellite welding machines for
high performance condition requirements.

Nitriding / Hard Chrome Plating

Nitriding and Hardchrome Plating On ATA valves enchances the valve life for
high speed and high combustion Engines.

Induction Hardening
Valve seat and Stem End hardening is processed by Electric
Induction Hardening Machines. Tip Welding are performed on
special requirements

19

Grinding
Centreless grinding at Stem and Cylinderical grinding
processes at seat area finishes ATA valves with high tolerance
requirements
Inspection
After strict stage Inspections, Final Inspection assures a defect
free delievery ATA valves to customers.

20

21

ENGINE VALVE OUTLINE

22

UPSETTING PROCESS PARAMETRIC STUDY ON

ENGINE VALVES

The current valve design and manufacturing process follows the Trial and Error
method, fixing an assumed data on any parameters and then giving a trial run on
the assumed parameters and then verifying it and fixing the standards.
This procedure may not be successful for all kinds of valves. It may lead to heavy
loss in the material stock, loss in time, loss in money, loss in labour, etc. So to
avoid these losses, standardization in the technique of manufacturing of valves is
mandatory. And the most important step in the valve manufacturing process is
Upsetting process. The entire valve design is based on the upset process and the
bulb formed due to the upsetting process.

Objectives

To study the upsetting process in the engine valve manufacturing process

To analyze and denote the parameters involved with the process and the
work material

To dimension the parameters obtained for several patterns

To correlate the parameters for every pattern

To wind up with a relation for the dependent and varying parameters

To denote a standard relationships to the parameters which influence the

Upsetting process in the manufacture of engine valves

23

Present system of Engine valve manufacturing process commonly receives the

following data,
Raw material details
Valve head diameter
Valve seat diameter
Overall Length of the valve
Seat angle
Stem length
Stem diameter

These data are only applicable to the valve design and for inspection and testing of
valves, but the other parameters involved in the manufacturing process are not said
or defined.
Such parameters include,
Upsetting time
Upsetting pressure & Return pressure
Voltage & current to be set during Upsetting process
Temperature to be maintained during Upsetting process
Length & Diameter of the raw material for a specific Valve
head diameter
Material to be chosen

24

As per the current system there is no direct relation between the raw material
parameters and the finished valve parameters. So a standard technique is not
possible to be put forth for the valve manufacturing process especially to the
upsetting process.
So to arrive at the parameter relationships, a detailed study is made on the
upsetting process in the Valve manufacturing process. The current process is
carried out as follows,
(i)

The raw material is chosen as per the desired Valve design and it is
cut into several cut-bars.

(ii)

The cut-bars are sent to the shops and they are inspected for the
diameter and length.

(iii)

Then 5 pieces of cut-bars are selected and they are placed over the ram of
the Electric Upsetting machine and then the ram movement distance is
adjusted based on the bulb to be formed

(iv)

Then other parameters like Upsetting pressure, Return pressure,

Temperature of the anvil, Voltage, Current are set on an assumption

(v)

Then the upsetting process is carried out on Trial basis, and then the
upsetted material is sent for forging

(vi)

The Forging die consists of the design of the valve to be obtained and the
forging operation is done

(vii) Then the five pieces are checked for any dimensional variations, if there
are no variations the process is further preceded, but when there are
occurrences of variation, the respective parameter is varied and then
again the same procedure is repeated.

Obviously, this sounds to be a tedious process and hence a technique is needed to

simplify the upsetting process.
25

PROJECT PLAN:

A set of samples of different patterns of valves are chosen based on criteria

like Head diameter, customer, Overall length, Material, Type of the valve.

Then the materials are upsetted using the Electric Upsetting process.

The parameters related to the upsetting process are noted down and then
they are analyzed.

The parameters for all the patterns are grouped and they are correlated.

The variations are noted down and the possible and effective ratios are
zeroed down.

These ratios are analyzed and standard relations are obtained.

26

27

COLLECTION OF DATA:
Particular 5 patterns are chosen and 10 samples are chosen.
After upsetting, the cut-bars get decreased in length and a certain part of the
material is bulged at the upsetted end resulting in bulb-like formation (here-on
called as Bulb).
This bulb actually looks in the form of a sphere but due to frictional effect it seems
to be irregular.

28

Raw material parameters are denoted as,

Lr Length of the raw material
Dr Diameter of the raw material

Bulb dimensions are denoted as specific parameters

A Upper diameter or Minor diameter of the bulb
B (or) Du Major diameter of the bulb
C Distance between the Minor diameter axis and the Major diameter axis
D Distance between the Minor diameter axis and the edge of the bulb (a) Height
of the bulb
E Fillet between the stem and the bulb
F Fillet between the upper edge and side of the bulb
G Outer edge fillet (only for one sample)
Lu Overall length of the sample obtained after upsetting
Vu Volume of the bulb
mu Mass of the bulb

29

30

31

Valve parameters are denoted as (after forging),

Df Diameter of the forged head
Vf Volume of the forged head
mf Mass of the forged head
Lf Length of the forged valve
Lh Length of the forged head

Other parameters are denoted as,

tup Upsetting time
Pu Upsetting pressure
Pret Return pressure
vu Upsetting Velocity
T Temperature maintained during upsetting process

After all these data are collected, they are tabulated.

32

Before Forging
A

B or Du
(all

C
dimensions

E
mm)

in

Lu

Mass (kg)

Volume (Vu)
3
(m )

Pattern 1

21.75

28.65

7.64

21.69

5.602

1.44

139.96

0.06777

529.2837

Pattern 2

10.04

15.94

5.27

14.1

5.37

3.144

103.6

0.01294

101.0614

Pattern 3

20.306

27.596

8.206

24.272

2.32

2.65

144.96

0.07964

621.9884

Pattern 4

10.641

17.928

6.3135

15.224

3.367

2.211

106.75

0.01771

138.3151

Pattern 5

9.927

15.1225

3.224

17.6235

2.005

1.926

88.98

0.01672

130.5832

Table - 1

After Forging
Diameter (Df)
(all

Head length
dimensions

O Length
in mm)

Pattern 1

40.76

16.23

138.48

0.06623

517.2563

Pattern 2

25.04

9.2

100.43

0.01242

97.0002

Pattern 3

40.98

23.452

137.13

0.08161

637.3741

Pattern 4

27.69

11.056

102.12

0.0176

137.456

Pattern 5

28.08

13.31

83.04

0.0172

134.332

Table - 2

33

Mass (kg)

Volume (Vf )
(m3 )

CORRELATION OF DATA:
Then the parameters are completely analyzed for the variations by correlating them
to a graph and their average values are quoted down.
Then the Volume of the bulb is obtained by simpler relation between the mass and
the density of the bulb material.
For steel, the density value is 7810 kg/m3
And hence, Volume = Mass / Density.
Thus Vu is obtained for each pattern and samples.
Then the most effective ratios which make a major shift to the upsetting process
are analyzed and selected. Here the following parameters influence more on the
upsetting process

B or Du

Vu

Df

B (or) Du

Vu

Vf

The variations are read as ratios and the following ratios play a major role in
denoting the upsetting process parameters

34

Df / Du

Vf / Vu

B/D or Du / D

A/B

A/D

Pattern 1

1.422688

0.977276

1.320885

0.759162

1.002766

Pattern 2

1.570891

0.959815

1.130496

0.629862

0.712057

Pattern 3

1.484998

1.024736

1.136948

0.735831

0.836602

Pattern 4

1.544511

0.993789

1.177614

0.593541

0.698962

Pattern 5

1.856836

1.028708

0.858087

0.656439

0.563282

Avg

1.575985

0.996865

1.124806

0.674967

0.762734

Table 3

Du / Df

Lu / Lr

D / Dr

Lr / D

Pattern1

0.702895

0.553202

2.357609

11.66436

3.11413

Pattern2

0.636581

0.643782

2.473684

11.06383

2.796491

Pattern3

0.673402

0.540896

2.582128

11.04153

2.935745

Pattern4

0.647454

0.586538

2.670877

11.95481

3.145263

Pattern5

0.538551

0.71184

3.175225

10.21421

2.724775

Average

0.639777

0.607252

2.651905

10.21421

2.943281

Table 4

35

Du / Dr

And arriving at a point, we come with the following variation graphs

Df / Du

1.9
1.8
1.7
Df / Du ratio

1.6
1.5
1.4
Df / Du

1.3
1.2
1.1
1

Df / Du 1.422687609 1.570890841 1.484997826 1.544511379 1.856835841

Patterns

Vf / Vu
1.05

Vf / Vu

0.95

0.9

Vu / Vf

0.85

0.8

Vu / Vf 0.977276081 0.959814529 1.024736313 0.99378882 1.028708134

Patterns

36

A/B
0.8
0.7
0.6

A/B

0.5
0.4
A/B

0.3
0.2
0.1
0

A/B 0.759162304

0.629861982

0.73583128

0.59354083

0.656439081

Patterns

A/D
1.2
1

A/D

0.8
0.6
A/D

0.4
0.2
0

A/D 1.002766252

0.712056738

0.836601846

0.698962165

0.563281981

Patterns

37

B/D
1.4
1.3
1.2

B/D

1.1
1
0.9
B/D
0.8
0.7
0.6
0.5

B/D 1.320885201

1.130496454

1.136947924

1.177614293

0.858087213

Patterns

38

Thus we can conclude with the following relations

D = 2.651905* Dr

Du = 2.943281* Dr

So, from this we know that when the Raw material diameter (Dr) is given
then the bulb height (D) and bulb major diameter (Du) can be obtained.

Lu = 0.61 * Lr

We also know the raw material length and hence we can obtain the Length
of the upsetted valve.

And all these parameters give the basic dimension details of the valves before and
after forging. For upsetting process, certain parameters like Pressure, Temperature
are needed to be set up with certain standards. So the obtained data and relations
are not enough. So a detailed analysis is made and the inference of upsetting
velocity (vu) is needed.
vu = Upsetting distance / Upsetting time

Upsetting distance is given as the variation in the length of the cut-bar after
upsetting.

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So upsetting velocity obtained is,

MATERIAL

Pattern 1

Pattern 2

Pattern 3

Pattern 4

Pattern 5

X45

SUH 11

21-4N

SUH 11

SUH 38

Pu (Upsetting pressure) kg/cm

35

40

40

40

18

113.04

55.57

123.04

75.25

36.02

13

6.6

21

6.8

12.9

8.695385

8.419697

5.859048

11.06618

2.792248

Dr (Raw material dia) mm

9.2

5.7

9.4

5.7

5.55

Lr (Raw material length) mm

253

156

268

182

125

Du (Bulb dia) mm

28.65

15.94

27.596

17.928

15.1225

Df (Forged head Dia) mm

40.76

25.04

40.98

27.69

28.08

D (Bulb height) mm

21.69

14.1

24.272

15.224

17.6225

Lr - Lu (Change in Cut bar length due to Upsetting) mm

tup (Upsetting time) sec
vup (Upsetting velocity) mm/s

Table 5

Whereas, the Upsetting Velocity becomes a function of the following parameters,

o Temperature
o Upsetting time
o Length of the cut-bar or raw material
o Thermal conductivity of the material
o Density of the material
o Mass of the material

40

Inferences:
1) The Upsetting pressure is dependent on the Composition of the material &
diameter of the raw material.
2) The Upsetting velocity depends upon the Upsetting length, upsetting
pressure and type of the material.
3) The upsetting bulb formation is directly proportional to the electrical
resistivity of the material. Higher the resistivity, slower the upsetting
process.
4) The stem diameter of the valve is proportional to the valve head diameter
and the upsetted bulb diameter. So the upsetted bulb diameter and the valve
head diameter are mutually proportional.

Data sheet:
Given data:

Dr (Diameter of the raw material) = ______mm,

Lr (Length of the raw material)

= ______mm,

Df (Diameter of the forged valve) = ______ mm

1. Du (Diameter of the bulb after upsetting) = 0.64 x Df = ______ mm

2. D (Height of the bulb)

= 2.65 x Dr = ______ mm

3. Lu (Length of the upsetted valve)

= 0.61 x Lr = ______ mm

41

4. Pu (Upsetting pressure)

kg / cm2

Pressure variations

For Martensite (SUH11, SUH38) type of material upsetting pressure can be

20-40 kg/cm2

For Austenite (21-4N, X45) type of material upsetting pressure can be

1. 25-28 kg/cm2 for raw material diameter range 5 - 6.5mm
2. 35-40 kg/cm2 for raw material diameter range above 8mm.

5. tup (Upsetting time)

secs

Time variations

For SUH11, 21-4N, X45 materials Upsetting time ranges

1. from 6 7 seconds for the raw material length of 150 180 mm
2. from 8 13 seconds for the raw material length of 180 255 mm
3. from 15 21 seconds for the raw material length above 255 mm

6. Ram pre-setting length

= Lr - Lu = ______ mm

The ram movement in the Electrical upsetter is responsible for the

determination of the upsetted bulb`s height. The distance through which the
ram must move is set by the distance Lr - Lu so that the required bulb
diameter and the height are obtained.
42

Advantages of the proposed system:

Material loss and scrap loss is reduced
Time effective process
Updating the design and the process is possible
Easier operation and work flow
Quicker setting of the parameters
Increment in productivity is evident
Capital and manufacturing cost are reduced

43

CONCLUSION:
These conclusions are derived based on the sampling of the data obtained by
certain valves manufactured at the premises according to the customer standards
and the proposals made by these conclusions may admit that a better standard of
working in the Upsetting process involved in the manufacturing of engine valves.
If these proposals are carried out there may be an advantage of improvement of the
process parameters and wastage of material with reduction in time.
This proposal may reduce the work load and the parameter settings based on trial
and error methodology. A straight-away setting of the parameters may result in
increased productivity and improvement in the work flow in the shops.
The obtained results allow for supposing that larger individualization in
determining the limiting dependencies is necessary. It will be useful for more
effective technological applications of the given process for different material.
Thus the proposal may be carried forward for betterment in the procedure of
Upsetting process.

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