forgings- a study of its manufacturing processes & techniques

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A FINAL/THIRD YEAR

MECHANICAL/ CIVIL ENGINNERING PROJECT REPORT ON

A STUDY OF FORGINGS

ITS TECHNIQUES

AND MECHANISMS


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1. ABSTRACT

The term “Forging” is applied to processes in which a piece of metal is worked in a machine

to the desired shape by plastic deformation of the starting stock. The energy that promotes

deformation is applied by a hammer, press, up-setter or ring roller, either alone or in

combination. The shape is imparted by the tools that contact the work piece and by careful

control of the deformation process. A forging is produced in three distinct phases: stock

preparation in the form of blooms, billets, bar or ingots; plastic deformation of the metal

component to rough, close tolerance or net shape in one of the forging processes; and

appropriate secondary operations

Forged metal components are used in wide range of environment where high strength

and reliability are important considerations. The use of forging is to reduce material wastage

and machining time, avoids complex machining operations and for mass production. Forged

components find application in the automobile/automotive industry and in aerospace, aircraft,

railroad, and mining equipment.

Metal forging process is governed by many factors such as friction, complexity of

parts, die shape and temperature of die and billet. In this study we are going to learn about the

principles of material selection, heat treatment, and the design calculations, which is involved

in forging of metal

This project is a study of the forging process, forgings defects, the forging machines

and their applications. In this project we also consider the manufacturing of crane wheels

through the closed die forging process in which metal is plastically reshaped using dies. This

involves the steps like design and material selection based on its properties. Machinery

equipment’s used in forging are pneumatic hammer forging machines, furnaces, dies, band

saw machines etc. Closed die forging process is used to obtain the final product in close

tolerance. The furnace is the main equipment in which the billet is preheated to a temperature

of 1200 degrees centigrade and then forged into required shape. It offers a high strength-to-

weight ratio, toughness, and resistance to impact and fatigue.


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7. DEFECTS IN FORGINGS

Table 7.1: Forgings Defects and corresponding effects

forgings- a study of its manufacturing processes & techniques

Engineering