Professional Documents
Culture Documents
FORGED COMPONENT
[TITANIUM RING]
A MINI PROJECT WORK IN THE PARTIAL FULFILLMENT OF THE DEGREE
BACHELOR OF TECHNOLOGY IN
MECHANICAL ENGINEERING
BY
S. SAMBHU PRAKASH (07241A03B1)
(Internal guide)
G.R.I.E.T
ABSTRACT:
S. SAMBHU PRAKASH
K. KRISHNA CHAITANYA
K. VAMSI KRISHNA
P. YASHWANTH KUMAR
ACKNOWLEDGEMENT:
S. SAMBHU PRAKASH
K. KRISHNA CHAITANYA
K. VAMSI KRISHNA
P. YASHWANTH KUMAR
G.R.I.E.T
(Affiliated to Jawaharlal Nehru Technological University, Hyderabad)
CERTIFICATE
The results and information embodied into his mini project report have not been
submitted to any other university or institution for the award of any degree or
diploma.
ORGANIZATIONAL PROFILE:
1) Forging
Cut to lengths.
INDEX
1.0 Introduction 9
3.1 Up-setting
3.2 Roll-forging
9.0 Conclusion 30
10.0 Bibliography 31
Temperature calibrator.
Metallurgical microscope.
HISTORY:
1.0 INTRODUCTION:
Forgings are consistent from piece to piece, without any of the porosity, voids,
inclusions and other defects. Thus, finishing operations such as machining do not
expose voids, because there aren't any. Also coating operations such as plating or
painting are straightforward due to a good surface, which needs very little
preparation.
Forgings yield parts that have high strength to weight ratio-thus are often used in
the design of aircraft frame members.
10
Open Die Forgings / Hand Forgings: Open die forgings or hand forgings are made
with repeated blows in an open die, where the operator manipulates the work piece
in the die. The finished product is a rough approximation of the die. This is what a
traditional blacksmith does, and is an old manufacturing process.
Impression Die Forgings / Precision Forgings: Impression die forgings and precision
forgings are further refinements of the blocker forgings. The finished part more
closely resembles the die impression.
Design Consideration:
11
Aluminum 0-2
Steel 5-7
12.5 1.5 5
(0.5) (0.06) (0.2)
12
25 3 6.25
(1.0) (0.12) (0.25)
50 5 10
(2.0) (0.2) (0.4)
100 6.25 10
(4.0) (0.25) (0.4)
400 22 50
(16) (0.875) (2.0)
Ribs should not be high or narrow; this makes it difficult for the material
to flow.
Forging temperature is a temperature at which a metal becomes soft like clay or its
shape can be changed by applying a relatively small force without creating cracks in
metal.
Note: Temperatures for alloys (combination of metals) will lie between the
temperatures specified for the metals utilized.
13
2.2
Hand forging:
Iron or steel heated and hammered to shape without the use of "closed dies". Drop
forging uses "closed dies". Other than moving the piece from one cavity to the next
there is no human input to the shape of the finished piece, the dies do it. Hand
forging involves hammering the heated metal on an anvil - the movement of the
material and the finished form are determined by the smith as the material is
moved under the hammer. Each piece is slightly different. If you find "Hand
Forged" and a barcode on plastic packaging is suspicious.
14
1. Anvil
2. Swage block
3. Tongs
4. Hammers
5. Chisel
6. Fullers
7. Flatters
8. Punches
9. Drifts.
15
16
undeformed. Another advantage to the process includes the knowledge of the new
parts strain rate. We specifically know what kind of strain can be put on the part,
because the compression rate of the press forging operation is controlled.
1. Swages
2. Hot cutters
3. Tongs
4. Pinch-bars
5. Spreaders
6. Charging bars
17
Tongs Chisel
1. Up setting
2. Roll forging
3. Piercing
4. Flattening
5. Drawing
6. Shaping
18
Upset forging increases the diameter of the work piece 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.
19
of this process is there is no flash and it imparts a favorable grain structure into the
work piece.
Ferrous metals:
20
3. Stainless steel 1200
Non-Ferrous metals:
Non-ferrous metals do not contain iron as the main
constituent. Generally they are weaker than ferrous metals but have other
important properties such as corrosion resistance, high electrical and thermal
conductivity, good formability and special electrical & magnetic properties the
chief non-ferrous metals used in the industrial purpose are copper, aluminum,
zinc, lead, tin, magnesium and their alloys.
21
S.NO NON-FERROUS FORGING TEMP
METALS IN C
1. Brass 650-800
2. Bronze 825-900
22
Continuous furnaces
Oil furnace
Pit furnace
Specifications:
Features:
23
A quality range of Box Type Furnace that is insulated with high quality
refractory bricks so as to minimize the heat. These furnaces are known for their
temperature control accuracy and quality of the insulation that ensure
maximum performance and efficiency. Further, rapid combustion is maintained
by the current of air under pressure.
24
Specifications:
25
26
ground level.
Height 625mm
Round 500mm
27
They are as follows:
5. Required operations
Up-setting
Punching
Roll forging
Flattening
7. Hardness checking
8. Proof machining
9. Ultrasonic test
10. Dispatch
Manufacturing Process:
Forging Process Flow Chart:
28
Machining Process Flow Chart:
29
Advantages:
9 More uniform structure with directional characteristics.
30
9 Smooth surface, closers dimensions permitting less machining.
Disadvantages:
9 Size is limited
31
9 To observe strictly all labour safety laws and all safety engineering
rules and regulations during work.
9.0 CONCLUSION:
10.0 BIBLIOGRAPHY:
9 WWW.WIKIPEDIA.ORG
32
33
34
35
36