ATMIYA INSTITUTE OF

TECHNOLOGY AND SCIENCE

Simulation and Experimental

validation of unfilling defect
found in connecting rod in
close die forging

Prepared by: Guide:

Rohan K Soyaliya Asst. Prof. Keyur V. Parmar
ME Production M.E(CAD/CAM) 1
Enroll no:140030728008 AITS Rajkot
Outline
• Introduction
• Company Overview
• Problem definition
• Objectives
• Literature review
• Research gap
• Methodology
• Die Models in CREO
• Proposed work of DP2
• Work plan of DP2
• References 2
Introduction
• Forging process of connecting rod –close die forging
1)Cutting long rods(raw material) of EN9 steel into 65×65mm
using band saw or billet shearing machine

2)Heating billet to forging temperature in oil fired furnace i.e

1050-1300 C

3
3)Placing heated billet in between upper and lower die and
carring out two step forging process i.e
i)Rolling-To elongate the square billet.
ii)Finishing-To get final shape of connecting rod.

4
Company Overview
• Millennium Forging Pvt Ltd. is a renowned name in the
field of Manufacturing of close die forgings as well as
finished forgings.
• Some of the products manufactured are connecting rod,
crank shafts, pipe fittings, Auto parts, gears, pinions.

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Problem definition
• In this dissertation work, defects found in the connecting
rod made from close die forging were analyzed. Defects
found were unfilling , lap, cracks ,scale pits .
• Inspection report of connecting rod(Aug-Nov 15’)

Month No Unfilling Lap Crack Scale pit

August 500 10 1 0 0

Sept 500 8 2 1 1

Oct 500 9 0 2 1

Nov 500 9 0 1 1

2000 36 3 4 3
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• From the inspection report ,it is clear that out of 46 defects,36 defects were
due to unfilling of material in die.
• Cause and Remedial measure of unfilling defect were found from literature
survey and discussing with industrial guide.

• Cause: Poor heating, less raw material , improper die design.

• Remedial measure: Proper heating i.e in limit of forging temperature
range ,proper raw material and die design.

• From the remedial measure ,proper heating is key factor for unfilling
defect and company laid more importance on temperature of billet during 7
forging.
Objectives
• To reduce the unfilling defect in connecting rod.
• To find the optimum temperature range at which no
unfilling defect is found using FEM based software
DEFORM 3D in which flow of material in die cavity can
be visualized.
• To carry out experiments to validate the result of
DEFORM 3D.

8
Sr
Literature Review
Title Author Conclusion Publication
no
1 An Overview of Mahendra Causes and remedial International
forging process Rathi,Nikes measures of the unfilling Journal of Scientific
with their defects h, defects are and Research and
Jakhade discussed.Proper heating publication Vol 4
reduce the unfilling defect. June 14’
2 Simulation and Piyush Unfilling defect analyzed in International
Optimization of Gulati,Raje DEFORM Journal of
material flow sh software.Validation is done Mechanical
forging defect in kanda,J.P statistically using Analysis Engineering and
automobile singh,Manji of Variance in MATLAB. Technolgy,Vol 3,
component and nder Bajwa Jan-April 13’
remedial
measure using
deform software

3 A six sigma M.S Quality tools of six sigma International

approach to Shekhon, are used to detect the Journal of
detect forging Dr G.S defects. In pareto chart Engineering and
defects in a small Brar,Dr 83% defects cracks, Technical Research
scale industry Sukhraj unfillings,pits were Vol 2,Issue 8 Aug
Singh observed. 14’
9
Sr Title Author Conclusion Publication
no

4 A grey-based Md. Israr Using taguchi 3rd International

Taguchi method to Equbala , method ,forging load Conference on
optimize hot Randhir kumar, and billet Materials Processing
forging process Mohammad temperature are and Characterisation
Shamim, R.K. optimised. (ICMPC 2014)
Ohdard Elsevier.

5 Influence of anvil Takefumi FE analysis is used 11th International

shape of surface Arikawaa,Daisu to evaluate the Conference on
crack generation ke Yamabeb, surface crack. Technology of
in large hot Hideki Maximum value of C Plasticity, ICTP 2014,
forging process Kakimotoc factor found at 19-24 October 2014,
defect region Nagoya Congress
Center, Nagoya,
Japan. Elsevier.
6 Controlling Aju Pius Simulation software International Journal
measures to Thottungal,Sijo are suggested for of Scientific and
reduce the M.T determining the Research Publication
rejection rate due material flow i.e for Volume 3,Issue 3
to the forging defects like unfilling March 2013
defect
10
Sr Title Author Conclusion Publication
no
7 Study of Christy Corrective measure for International Journal of
Forging Mathew, unfilling defect Engineering and
Defects in Justin suggested is proper Innovative Technology
Integral Axle Koshy, Dr. Scale (IJEIT) Volume 2, Issue
Arms Deviprasad removal.Temperature 7, January 2013
Varma and design aspect are
also factors affecting it
8 Forging Basavasag Simulation of Rocker International Journal of
simulation of ar, Prof. arm done using AFDEX Engineering Trends and
Rocker arm Bharat S software. Material Flow Technology (IJETT) –
using AFDEX Kodli analysis is done at each Volume 25 Number 4-
software stage to know about die July 2015
cavity filling.

9 Simulation of Mahdi Simulation of gear done 2012 International

finite volume of Maarefdou using Super forge Conference on
hot forging st software. Temperature Networks and
process of and coefficient of friction Information (ICNI 2012)
industrial gear will affect effective IPCSIT vol. 57 (2012) ©
stress and plastic strain. (2012) IACSIT Press,
Singapore

11
10 Billet Sorting A.D. Gunka, Billet sorting technique International Journal
Mechanism for 2A.D. Jadhav, used to short billet. If of Recent Research in
Reducing the A.L. KIRAD, billet are not in the Civil and Mechanical
Rejection Rate in T.S. Dimble forging temp range, Engineering
Forging Operation they are send back to (IJRRCME) Vol. 2,
the furnace again using Issue 1, pp: (36-47),
pneumatic technique. Month: April 2015 –
September 2015.
11 Experimental J.Babua, Abhijit Deformation 3rd International
Studies on Effect of Duttab, A temperature and strain Conference on
Temperature and Kumaraswamy rate affect mechanical Materials Processing
Strain Rate on properties. Optimum and Characterization
Deformation temp and strain rate are (ICMPC 2014)
Behavior of Ti-6Al- found using the taguchi Elsevier
4V using Taguchi method
Method
12 FEM simulation of I. Poláková, M. Crack initiation was due International
open die forging Duchek, L. to decrease in Scientific Journal
of a plate from Maleček temperature of edge published monthly by
material NIMONIC plate. DEFORM 3D is the
80A effective tool to detect World Academy of
in DEFORM 3D material flow defects Materials
and Manufacturing
Engineering
Research Gap
• From the literature review done ,In paper 1 defects found
during the forging process are discussed. Among that
cause and remedial measure for unfilling defects are
discussed.Proper heating of the billet in optimum
temperature range is remedial measure to reduce
unfilling defect.
• From paper 2, I found that material flow analysis in die
cavity of automobile component done using DEFORM
3D.
• At last stage in simulation, we can visualize the material
flow in die cavity. Optimum temperature is found during
simulation i.e at that temperature no unfilling defect
found,validation of the software done statistically in
MATLAB.But to find exact final condition, experiments 13
are to be carried out
Methodology
• General defects found in forging products.
• Finding defects that are found in the connecting rod
1 i.e cracks laps, scale pits, unfilling .

• From the inspection report it is found that unfilling

defect contributed more to rejection.
• Finding the cause and remedial measure of unfilling
2 defect

• An unfilling defect is material flow defect so finding tool

to analyze the defect.
3 14
 • Simulation to be carried out in DEFORM 3D to find
the optimum temperature range.
• Using all input parameters in pre-processor
4

• Creating upper and lower die model in CREO

• Importing model in DEFORM 3D in .STL format and
placing billet in between them.
5

• Determining optimum temperature range from

simulation where there is complete filling of die cavity
• Experiments are to be carried out in optimum
6 temperature range to validate DEFORM 3D
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Model of Upper and Lower die in
CREO

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17
Upper and lower die

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Proposed work of DP2
Importing the upper and lower die in .STL format in pre-
processor of DEFORM 3D
Input parameters to be needed in pre-processor
1)Material of die and connecting rod
2)Temperature of material
3)Object meshing
4)Forging load
5)Positioning of billet.
After inputting all parameters, simulation is started in the
simulator module.
Results can be viewed in the post processor module of the
19
software.
After finding an optimum temperature range where there is
complete filling of die cavity.

Experiment to be carried out with same step except,

heating the billet within the optimum temperature range
found .
Experimental results to be found to validate DEFORM 3D.

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Work Plan DP2
Week 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20
Jan Jan Jan Jan Jan Feb Feb Feb Feb Mar Mar Mar Mar Apr Apr Apr Apr Apr May May
Starting
1 8 15 22 29 5 12 19 26 5 12 19 26 2 9 16 23 30 7 30

Cre ating the rolled

Phase mode l and doing
simulation

Fullfill the
two
comments
Te mpe rature range
from simulation and
comparing
Result
analysis
Write
re se arch
paper &
publishing
Pre paration of
mid se m
Fulfill Midsem comme nts

Conducting
e xperiments in
Company

Validation of
21
re sults

Pre paration &

demonstration
for final thesis
References
1) Mahendra G. Rathi, Nilesh A. Jakhade, “An Overview of Forging Processes with
Their Defects” International Journal of Scientific and Research and publication Vol 4
June 14’
2) Piyush Gulati, Rajesh Kanda, JaiInder Preet Singh, Manjinder Bajwa, “Simulation
and Optimization of Material Flow Forging Defects in Automobile Component and
Remedial Measures Using Deform Software” International Journal of Mechanical
Engineering and Technolgy,Vol 3, jan-apl 13’
3) Meetinder Singh Sekhon, Dr. Gurinder Singh Brar, Dr. Sukhraj Singh, “A six sigma
approach to detect forging defects in a small scale industry: A case study”
International Journal of Engineering and Technical Research Vol 2, Aug 14’
4) Md. Israr Equbala , Randhir kumar,Mohammad Shamim, R.K. Ohdard, “A grey-
based Taguchi method to optimize hot forging process” 3rd International Conference
on Materials Processing and Characterisation (ICMPC 2014)
5) Takefumi Arikawaa,,Daisuke Yamabeb, Hideki Kakimotoc, “Influence of anvil shape
of surface crack generation in large hot forging process” 11th International
Conference on Technology of Plasticity, ICTP 2014, 19-24 October 2014, Nagoya
Congress Center, Nagoya, Japan
6) Aju Pius Thottungal,Sijo M.T, “Controlling measures to reduce the rejection rate
due to the forging defect” International Journal of Scientific and Research Publication 22
Vol 3, March 2013
7) Christy Mathew, Justin Koshy, Dr. Deviprasad Varma, “Study of Forging
Defects in Integral Axle Arms” International Journal of Engineering and
Innovative Technology (IJEIT) Volume 2, Issue 7, January 2013
8) Basavasagar, Prof. Bharat S Kodli, “Forging simulation of Rocker arm using
AFDEX software” International Journal of Engineering Trends and Technology
(IJETT) – Volume 25 Number 4- July 2015
9) Mahdi Maarefdoust, “Simulation of finite volume of hot forging process of
industrial gear” 2012 International Conference on Networks and Information
(ICNI 2012) IPCSIT vol. 57 (2012) © (2012) IACSIT Press, Singapore
10) A.D. Gundka, A.D. Jadhav, A.L. Kirad, T.S.Dimble, “Billet Sorting
Mechanism for Reducing the Rejection Rate in Forging Operation”
International Journal of Recent Research in Civil and Mechanical Engineering
(IJRRCME) Vol. 2, Issue 1, pp: (36-47), Month: April 2015 – September 2015
11) J.Babua, Abhijit Duttab, A Kumaraswamy, “Experimental Studies on Effect
of Temperature and Strain Rate on Deformation Behaviour of Ti-6Al-4V using
Taguchi Method” 3rd International Conference on Materials Processing and
Characterisation (ICMPC 2014)
12) I. Poláková, M. Duchek, L. Maleček, “FEM simulation of open die forging of
a plate from material NIMONIC 80A in DEFORM 3D” International Scientific
Journal published monthly by the World Academy of Materials and 23
Manufacturing Engineering
Websites
www.highpeaksteels.com
THANK YOU

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