1. SRIDHER REDDY
FORGING

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Introduction of FORGING
•Forging is one of the metal forming process
• The oldest of the metalworking arts (primitive
blacksmith).
• Forging is the working of metal into a useful
shape by hammering or pressing.
The forging process can create parts that are stronger than
those manufactured by any other metalworking process. This
is why forgings are almost always used where reliability and
human safety are critical.
• Forging machines are now capable of making
parts ranging in size of a bolt to a turbine
rotor.
• Most forging operations are carried out hot,
although certain metals may be cold-forged.

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Heating the material above re-crystallization
temperature

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Why forging only

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FORGIN GRAIN FLOW of stub axel
Optimizing grain flow
orientation maximizes
mechanical properties.

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Forging Applications
(Chasses parts and engine parts) Crank shaft, connecting rod, cam shaft, steering arms, stub axils, valves, gear
shift fork, differential casings, etc.

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Just about any metal can be forged. However, some of the most common metals
include: carbon, alloy and stainless steels; very hard tool steels; aluminum; titanium;
brass and copper; and high-temperature alloys which contain cobalt, nickel or
molybdenum. Each metal has distinct strength or weight characteristics that best apply
to specific parts as determined by the customer.
Temperature may vary from metal to metal and depending on chemical compositions
What metals are forged?

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Types of FORGING

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OPEN DIE FORGING
• Open-die forging is carried out between flat dies or dies of
very simple shape no precut profiles. (LARGER OBJECTS AND SMALL PRODUCTION)

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CLOSED OR IMPRESSION DIE STEEL FORGING
The work piece is deformed between two die halves (called tooling) which
carry the impressions of the desired final shape.
• The work piece is deformed under high pressure in a closed cavity.
• Normally used for smaller components.
• The process provide precision forging
with close dimensional tolerance.
• Closed dies are expensive.
The grain flow of the metal can be controlled
Ensuring high mechanical properties.
Forging of complicated shapes can be made
Forging s are made with smaller machining
allowances

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M/C Allowance
IN FORGING WE CAN NOT GET THE FINISHED PRODUCT
Before design the forge part should consider, all allowances blow shown
Shrinkage allowance
1.1% to 1.6%

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Raw material inspection Raw material cutting
Band saw/shearing M/C
Raw material heating
Induction heating/oiled fire Furness
1100-1200 centigrade
Forging (2000T)
Pre-shaped (flattening)
Blocker (rough shape)
Finisher
Trimming
(150T)
Linishing /Grinding
To remove excess flash
Heat treatment
Hardening and Tempering
Normalizing, Stress reliving
Hardness testing
BHN test M/C
Coining Magnaflux checking
(Crack free forging)
DemagnetizingFinal inspection
Rust prevention
(DWX-32 oil)
Packing & dispatch
Closed die Forging Process flow chart
Shot blasting

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FORGING RAW MATERIAL
SCS
RCS
ROUND
BARSS

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BAND SAW M/C
Sawing MachinesSawing Machines
Swaging is used to produce a bar/Rod with a smaller pieces
Advantages is good
dimensional accuracy
Disadvantage blade
will be cost, slow
production

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FORGING BILLETS CUTTING
SHEARING M/C
Disadvantage is high
force required, more
tolerance required,
shearing face will be
taper and chance to
break the material
WHILE UPSETTING
LAPS MY ACCURE
Advantages is fast
production

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BILLETS INSIDE OIL FIRED FURNESS
FURNESS OILE CONSIST OF SULFER CONTENT
DUE TO THIS OXIDIZATION WILL BE MORE
AND SCALING WILL BE MORE
TO AVIDE OXIDIZATION ADDING NITROGEN
OR NION

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1000 KW
INDUCTION FURNESS

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FORGE SHOPFORGE SHOP
Mechanical press — A forging press with an inertia
flywheel, a crank and clutch, or other mechanical device to
operate the ram.

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BOLSTER PLATES
Bolster plate — A plate to which dies can be fastened; the assembly is secured to the top surface of a press bed. In
press forging, such a plate may also be attached to the ram.
Movable bolster fitted in to
the top of the m/c bed
Fixed bolster fitted in to
the bottom of the m/c bed
Bottom dies
Top dies

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DIES
FLATTENING
dies (pre-shape)
Finisher die
Blocker die
Trim die
Fixed to the top
bolster

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Parting Surfaces
The plane that
divides the two
forging die
halves

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FORGING PRESS

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EDGING BLACKER FINISHER OPERATIONS

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Lubrication Purposes
• Reduce friction
•Reduce die wear
•Thermally insulate part
•Remove scales from the die
•Die cooling

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BEFORE TRIMING
Flash: excess metal that extends out from the body of the forging
to ensure complete filling of the finishing impressions.
• Acts as a ‘safety value’ for excess metal.

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TRIMING TOOL

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AFTER TRIMING
FLASH

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FORGED COMPONENT AFTER TRIM OPERATION

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FLASH SCRAP

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FORGING PRE OPERATION SHAPES
Billet
Pre-operations
(flattening)

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Pre-shape
Blocker
(semi finish)
Finisher
with flash

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Heat TreatmentHeat Treatment
Continuous H & T Furnaces withContinuous H & T Furnaces with
Water/Polymer/Oil QuenchingWater/Polymer/Oil Quenching
Batch Furnaces for Normalizing /Batch Furnaces for Normalizing /
Stress relievingStress relieving

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Heat TreatmentHeat Treatment

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BHN Testing M/CBHN Testing M/C

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Shot BlastingShot Blasting
Definition: Shot blasting consists of attacking the surface of a
material with one of many types of shots. Normally this is done
to remove something on the surface such as scale, but it is also
done sometimes to impart a particular surface to the object
being shot blasted, such as the rolls used to make a 2D finish.
The shot can be sand, small steel balls of various diameters,
granules of silicon carbide, etc. The device that throws the shot
is either a large air gun or spinning paddles which hurl the
shot off their blades.

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Shot Blasting M/C swing tableShot Blasting M/C swing table

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GRINDING m/c

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CoiningCoining
It is post-forging
process - on hot or cold
parts - to attain closer
tolerances or improved
surfaces.

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Crack TestingCrack Testing –– (Magnaflux Checking )(Magnaflux Checking )
AFTER MAGNAFLUX CHECK
DEMAGNATISING WILL BE
MUST

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Advantages and disadvantages
Reduced machining time
Improve the physical properties of the starting metal
Porosity in metal is largely eliminated
Impurities (inclusions) are broken up and distributed through the metal
Course grains are refined
Due to grain refinement, the physical properties are generally improved
» Ductility and resistance
High working temp. can result in rapid oxidation/scaling of surface = poor
surface finish
Generally, close tolerances are hard to control
Equipment and tool maintenance costs are high
» Usually not used for short production runs
» Die life is less

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DIE SHOPDIE SHOP

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DIE SHOPDIE SHOP

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MMT EDM Machine
DIE SHOPDIE SHOP

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CAD MODEL CRANKSHAFT TOP DIE

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CNC MEACHINES

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CNC DIE CUTTING (RE-CUTTING AFTER
PRODUCTION)

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CNC DIE CUTTING

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FORGING PRODUCTSFORGING PRODUCTS

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CONNECTING RODCONNECTING ROD
CRANK SHAFTCRANK SHAFT

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CENTER LINK
DIFFERENTIAL COVER

51. THANK YOU
SRIDHER REDDY