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DESIGN & FABRICATE A PROTOTYPE OF A FORGING PART FOR AN AUTOMOTIVE

INDUSTRY BY REVERSE ENGINEERING/CAD/CAM/CAE.


Rabia Siddiqui, Sanna Irfan, Sheheryar Mohsin , Sara Binte Ali
Advisor: MR. Ali Zulqarnain
Department of Industrial & Manufacturing Engineering
NED University of Engineering & Technology
WHAT IS FORGING?

NON TRADITIONAL MACHINING:

Forging is the process by which metal is heated and is


shaped by plastic deformation by suitably applying
compressive force.
Forging refines the grain structure and improves physical
properties of the metal. With proper design, the grain flow
can be oriented in the direction of principal stresses
encountered in actual use. Grain flow is the direction of the
pattern that the crystals take during plastic deformation.
Physical properties (such as strength, ductility and
toughness) are much better in a forging than in the base
metal, which has, crystals randomly oriented. .
Process parameters

Scanning

Part modelling
by using PRO-E

CNC machining centre

SELECTION OF ELECTRODE MATERIAL

Punch
Die

Electrode
Conventional machining
EDM wire cut

ELECTRODE
MATERIAL

FORM

COPPER

Bar, rod,
sheet,
wire,
tube,
forgings,
stamping
s

Electrode

Prototyping by EDM

CORNER
WEAR
RATIO IN
FINISHING

Process Parameters
END WEAR
RATIO IN
ROUGHING

RELATIVE
COST

MACHINABILITY
RATING

1:1

2:1

Medium

Dielectric fluid

Good

Depth setting
Polarity

Tool Path Generation


MACHINING PROGRAM PERAMETERS

NC Sequence name : Finishing


Operation name
: CNC Milling
Work Cell name
: machine 01
Work Cell type
: Mill
Axis Type
: 3-Axis
Cutting Time
: 57.75 min
NCL File Name
: Finishing
POST_PROCESSOR---P14

Entity Relationship Diagram

Frequency of discharge
Spark gap

CNC MACHINING

MAJOR TASKS OF THE PROJECT

Current in each spark

NC SEQUENCE PARAMETERS

Tool_ID : Tool 0001


Diameter : 8mm
Diameter : 6mm
Cut_Type : Conventional
Step_Depth : 0.3mm
Step_0ver : 10mm
Cut_Feed : 1800 mm/min
Spindle_Speed : 2000
rev/min
Coolant
: On

STRESS ANALYSIS(ANSYS)

Material Selection(die Block)


Composition of H-13

Material selected is chromium


type tool steel(H-13) as it
contains 1%Vanadium which
helps
in
increasing
the
forgeability.

Components

Weight (%)

0.32 - 0.4

Cr

5.013 - 5.25

Fe

Min 90.95

Si

Finding allowable working stress:


from the analysis:
Sw = Sm / F.O.S
stresses generated=
Where;
600Psi<<159Kip
Sw = Allowable working stress in psi.
Sm = Strength of material in psi.
F.O.S = 1.5
Sw = 159 kip

DIE CALCULATIONS

COST ESTIMATION

Size of Die Block(Length)


L=l+3h

OPERATION

DESIGNING

500

20
4
20
3

1200
320
2000
150

1.5

375

80

12800

Height of Die Block(Length)

[Ref. Book: PC Sharma (Page:

180)]

Where,
L = length of die block
l = total length of impression = 97.6mm
(Ref. Part drawing)

h = maximum depth of impression = 11.525mm


(Ref. Part drawing)

S.No.

PART NAME: 2P GEAR


DATE: Dec 24, 2005
RATE (Rs.)
HRS.
COST (Rs.)

L = 97.6 + 3 X 11.525
Therefore,
L = 132.15 mm
Selected size
= 150 mm

h
(mm)

H
(mm)

100

10

125

40

200

100

(Standard size available in market)

Rated Size of Hammer


Rated Size
(lb)

Power Drop
Max. Energy
(Ft-lb)

Gravity Drop
Max. Energy
(Ft-lb)

1000

11,100

3850

1500

16,700

5870

2000

22,500

8830

2500

28,500

11,320

3000

34,400

14,200

4000

46,000

19,400

5000

58,000

24,700

6500

70,000

30,000

8000

94,000

41,600

10,000

118,000

52,000

12,000

142,000

16,000

190,000

20,000

240,000

25,000

300,000

315

2
3
4
5
6
7
8
9
S.No.
10
11
12
13
14

250
MACHINE SHOP
LATHE (Turning)
60
SURFACE GRINDER
80
VERTICAL MILLING
90 - 100
RADIAL DRILL
50
SPM SHOP
CNC MILLING CENTRE
250
E.D.M.

160

MANUAL
DIE FITTING (Polishing)
50
50
OUTSIDE WORK
HEAT TREATMENT
60/KG
15
MATERIAL COST
MAT./PARTS USED
RATE (Rs.)
QTY.
H 13
320
26.15 kg
COPPER
380
0.589 kg
MILD STEEL
45
15kg
M12*50 (Bolts)
30/pc.
8 pcs.
OVERHEAD COST

20% OF DIE COST


TOTAL COST

Acknowledgements

2500
900
COST (Rs.)
8368
223.82
675
240
6050.4
Rs 36303/=

Continued collaboration of NED University of Engineering and


Technology and TAHA ENGINEERING is highly acknowledged.