REDUCTION OF FLASH BY SAVING CUT WEIGHT IN FORGING

Presented by
Animesh Sharma
18210002

Under the guidance of

Under the guidance of

Prof. RK Mahajan
Department of Materials and Metallurgical Engg.
Punjab Engineering College, Chandigarh
 INTRODUCTION
Forging:-
Forging is a manufacturing process involving the shaping of a metal through hammering, pressing, or rolling. These
compressive forces are delivered with a hammer or die. Forging is often categorized according to the temperature at
which it is performed—cold, warm, or hot forging.
Flash:-
Metal in excess of that required to fill completely the blocking or finishing forging impression of a set of dies. Flash
extends out from the body of the forging as a thin plate at the line where the dies meet and is subsequently removed by
trimming.

Advantages of forging:-
• Better fatigue resistance and strength.
• The process achieves very consistent material uniformity, which results in uniform mechanical properties.
•  Through proper deformation and grain flow, combined with high material uniformity, the forging process maximizes
impact toughness, fracture toughness.
 Literature Review
Sr. No. Publisher and year Title Conclusions
of publication

1. Jan Langner, Dr.-Ing. Investigation of a • A height of 2 mm of the moveable flash brakes, which
Malte Stonis, Prof. Dr.- moveable flash gap in hot represents the moveable flash gap, distinctly changes
Ing. Bernd-Arno forging the material flow compared to a conventional
Behrens (2016) forming process.
• With billet volume 120% and 125% less significant
change in height is observed this is due to the fact
that outer spaces are generally filled later and flash
brakes are retreated by then.
• The effect of movable flash gap decreases with
decrease in billet volume.
• As the temperature of the billet decreased from
1200deg c to 1000 deg c the difference in height
decreases as well, due to increase in the flow stress.
Sr. No. Publisher and year Title Conclusions
of publication
2. Mehmet Okan Görtan,
Fisun Yazicioglu, Oguz Literature Review
Investigation of Weight
Saving Potentials in
• Scale removal process is replaced with rod forward-
lateral extrusion.
Ozsoy (2019) Complex Steel • It enables a more homogenous mass distribution for
Forgings via Extrusion and the complex geometry part of the ball joint body
Forging Combination using part.
Finite Element Analysis • Flash generation is lowered compared to the initial
state.
• Contact pressure are significantly lowered in the leaf
section, suggesting lower wear and higher tool life
compared to the initial state.
 LITERATURE REVIEW
Sr. No. Publisher and Title Conclusions
year of
publication

3. B. Tomov, R. Radev, Influence of flash design •hf = 1.13 + 0.089√mF − 0.017mF

V. Gagov(2004) upon process parameters •Bf/hf= 3 + 1.25 exp(−1.09mF)
of hot die forging. •Above two equations can be used as a first step of
flash design
•The next step should involve an estimation of the
elastic deflections of both the die and the machine
being in consideration and then, if necessary, followed
by flash thickness correction.
Equations used by design team
in SAMRAT forging limited
 LITERATURE REVIEW
Sr. No. Publisher and Title Conclusions
year of
publication

4. Dorin Luca (2017) A numerical solution for a •For forging hammers

closed die forging Process h1 = 0.015 (Ap)^1/2
•Value calculated by this relationship can be
corrected(by increasing or decreasing the value of h1)
after examining how the flow of material for any type
of forged part.
•Equivalent stresses from forging tools vary inversely
with the flash land height.
•Forging forces decreases with increasing of the flash
land height however, increasing the flash land height
can only be made in the limits.
 Area of interest

• Understanding the flow of material under given conditions.

• Flash land dimensions are not being interfered during the process
simulations.
• Better design of the die according to the industrial environment.
• Softwares like Solid works and Deform 3D are to be used for the
simulation purposes.
 Objectives
• Reduction of flash in Forging by improving the cut weight of the part.
• Choosing the best setup of parameters(like design, cut weight) for
process so that we can reduce the errors in the process while also
keeping in mind that the input capital should not increased.
• Application of simulation software for less wastage of material and
time.
Work Plan and Methodology
Understanding the ground work on the given topic

Industrial Visit

Understanding the process and the parameters affecting the process

Designing the Proper Die for the products while also producing quality
product

Optimized parameters with reduced flash

Thank You