This document provides an overview of forging processes and techniques. It discusses open die and closed die forging, commonly forged materials like steels and aluminum alloys, hammers and presses used in forging, advantages of forging, potential defects, applications, secondary operations like heat treating and machining, product design considerations, safety measures, and details a site visit to Bharat Forge Ltd where connecting rods and front axles are produced.
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OPEN DIE PROCESS
• RING FORGING
– Slight rotation of the ring on each press stroke
reduces the ring wall uniformly and increases
both the inside and outside diameters. The
height of the ring remains nearly constant, but
may require edging
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ADVANTAGES OF FORGING METALS
• GREATER STRENGTH
• REDUCTION IN WEIGHT
• ABILITY TO WITHSTAND UNPREDICTABLE
LOADS
• MIN OF MACHINE FINISH REQUIRED
• SAVINIG IN MATERIAL
• ELIMINATION OF INTERNAL DEFECTS
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HEAT TREATING
• TO IMPROVE MECHANICAL PROPERTIES
OF FORGED COMPONENTS
• UNIFORM GRAIN STRUCTURE
• TO RELIEVE INTERNAL STRESSES
– ALL SEVEN GROUPS OF ALLOYS CAN BE
HEAT TREATED
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FINISHING OPERATIONS
-REMOVAL OF OXIDE SCALES
• WHY ?
– DURING MACHING CUTING TOOL LIFE
REDUCES
– DIE WEAR
– TO FACILITATE SURFACE COATING
# STEAM OR COMPRESSED AIR
# OIL SPRAYING
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FINISHING OPERATIONS
-CLEANING
• PICKLING
– IMMERSED IN ACID SOLUTION
– 12% TO 15% OF CONCENTRATED
SULFURIC ACID WITH WATER
– IN SOME CASES ACID SOLUTION IS
HEATED
– MOSTLY FOR NON FERROUS FORGINGS
(Cu, BRASS, BRONZE, Al, MONEL)
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FINISHING OPERATIONS
-CLEANING
• BLAST CLEANING
– SAND, GRIT OR METALLIC SHOT ARE
MIXED WITH AIR AND FORCED
AGAINST FORGINGS
– USED FOR SMALL AND MEDIUM SIZE
FORGINGS
– IMPROVES SURFACE FINISH
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FINISHING OPERATIONS
-SHOT PEENING
– ROUND METALLIC SHOT IS THROWN IN
RELATIVELY HIGH VELOCITY
– INCREASES THE FATIGUE STRENGTH
– PITTING
– CRANK SHAFTS, CAM SHAFT,
CONNECTING RODS, GEARS AND
SPRINGS.
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PRODUCT DESIGN OF FORGING
• CONSIDERATION FOR DESIGNING FORGED
PARTS
• CONSIDERATION FOR DESIGNING
FORGING DIES
• RECOMMENDED ALLOWANCES
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PRODUCT DESIGN OF FORGING
RECOMMENDATIONS :
•DRAFT
7° OUTSIDE DRAFT ANGLE
10° INSIDE DRAFT ANGLE
•RADII & FILLET SHOULD BE AS LARGE
AS POSSIBLE
•SHARP RADII SHOULD BE AVAILABLE
•IN CASE OF SMALL DEPRESSION OR
SMALL HOLES SHOULD BE MACHINED
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PRODUCT DESIGN OF FORGING
• AVOID DEEP IMPRESSIONS
• THIN WALLED SECTIONS SHOULD BE
AVOIDED
• RAPID CHANGE OF SECTIONS SHOULD BE
AVOIDED
DIE:
• THE PARTING LINE SHOULD BE
ARRANGED IN ONE PLANE AS NEARLY AS
POSSIBLE SO THAT EXCESS METAL OR
FLASH CAN BE TRIMMED
• INSERT DESIGN
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COMPANY VISITED
• BHARAT FORGE LIMITED, PUNE
– ONE OF THE ASIA’S BIGGEST
– ALMOST ALL AUTOMOTIVE LEADERS ARE
THEIR CUSTOMERS
– MANUFACTURING CRANK SHAFTS, FRONT
AXLE, REAR AXLE, CONNECTING RODS,
CAM SHAFTS etc