Question 1 – Forged Crankshaft

You are the manufacturing engineer in a forged component production facility. Figure 1 shows a plain
medium carbon steel crank shaft that you have been requested by a client to make. The client has
requested 30 crankshafts per day.

a) Identify 2 possible forging process candidates. Of these 2 processes, justify the ideal one for
production of this forged component.
(6 marks)

b) Using 2 sketches, show intermediate forging shapes to produce this crankshaft. Begin with the
starting stock shown in Figure 2.
(6 marks)

Figure 1. Crank shaft

Figure 2. Starting stock