Mapúa University

658 Muralla St., Intramuros, Manila

ME149F – PLANT INSPECTION TRIPS AND SEMINARS

ME149F/B1

TECHNICAL REPORT # 7

PLANT VISIT NO. 1

Sambrano, Dave V. Date Conducted: June 14, 2018

SN. 21 Date Submitted: June 18, 2018

2015110907

SCORE
Engr. Sublime Carvajal
Instructor
 TABLE OF CONTENTS

I. Objectives 3

II. Introduction 3

III. Theory/Hypothesis 4

IV. Discussion 4

V. Conclusion 5

VI. Recommendation 6

VII. Documentation 7

VIII. References 8

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I. Objectives

a. To explain what are the manufacturing processes involved

b. To tell what are the products produced

c. To explain how does the plant help in the industry

d. To better understand the mechanical world

II. Introduction

Manufacturing plants are a big factor in the industry since it will be

the source of some products needed for production of an item. These

plants are essential because they will help in creating a wider space and

another option for manufacturers to introduce innovation by processing

it in these plants. With the help of engineers, the quality of the product

is a big factor since it will benefit not only the producer but also the

consumer. It is important to know about how these places help in the

industry and how will it affect the future products here in the

Philippines. Innovation is important for an engineer because it will

determine how a product is a step ahead of the others and how it will

also help in increasing the quality of the product. Manufacturers are a

big factor in the industry since all of the products used in everyday life

are going under these manufacturers. These people are the responsible

for quality control and the checker of products if they can still be

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 manufactured, restored or recycle it for a better quality and a better help

for the consumer. Manufacturers are the people that will ensure that the

demand of the people are being delivered.

III. Theory/Hypothesis

Forging is a manufacturing process involving the shaping of metal using

localized compressive forces. The blows are delivered with a hammer (often a

power hammer) or a die. Forging is often classified according to the temperature

at which it is performed: cold forging (a type of cold working), warm forging, or

hot forging (a type of hot working). For the latter two, the metal is heated, usually

in a forge. Forged parts can range in weight from less than a kilogram to hundreds

of metric tons. Forging has been done by smiths for millennia; the traditional

products were kitchenware, hardware, hand tools, edged weapons, cymbals, and

jewelers. Since the Industrial Revolution, forged parts are widely used in

mechanisms and machines wherever a component requires high strength; such

forgings usually require further processing (such as machining) to achieve a

finished part. Today, forging is a major worldwide industry.

IV. Discussion
Forging is the optimum process, in terms of both part quality and cost,
especially for applications that require maximum part strength, custom
sizes or critical performance specifications.
Industrial Application of Forged Components:
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1. Automative and Trucks: Forged components are commonly foundAs we
know already, forged components are prepared with heavy pressures and
extreme forces. So they are acclaimed optimum solution for valves and
fittings industry. They are less resistant to corrosion, and flame resistant that
is taken suitable for flanges, vales, fittings, stems, saddles or elbows etc.
When vales would be extra strong, they can be used under heavy pressures
as well., kingpins, axle beams and shafts, torsion bars, ball studs, idler arms,
pitman arms and steering arms.
2. Agricultural Machinery & Equipments:
Strength, toughness and economy are important in farm implements. In
addition to engine and transmission components, key forgings subjected to
impact and fatigue range from gears, shafts, levers and spindles to tie-rod
ends, spike harrow teeth and cultivator shafts.
3. Hand Tools & Hardware Components:. Pliers, hammers, sledges, wrenches
and garden tools, wire-rope clips, sockets, hooks, turnbuckles and eye bolts
are common ly forged. Surgical and dental instruments are also often forged.
Special hardware for electrical transmission and distribution lines such as
pedestal caps, suspension clamps, sockets and brackets are commonly forged
for strength, dependability and resistance to corrosion.
4. Valve Fitting: As forged components are prepared with high pressure and
extreame force, they are often associated with Valve and Fitting industry.
Corrosion and heat-resistant materials are used for flanges, valve bodies and
stems, tees, elbow reducers, saddles and other fittings.

V. Conclusion

Today we will learn about what is forging and types of forging. Further

we will discuss about operation, application, advantages and disadvantages

of this process. Forging is a metal forming process in which the metal is

heated and a force is applied in such a way that a required shape can be

obtain. It is basically a hot working process in which the work piece is

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 heated up to plastic stage and the force is applied by manually or by press

according to the requirement. This force is compressive in nature which is

basic requirement of forging. Sometime forging operation is done without

application of heat known as cold forging. Now days, Forging is used in

every manufacturing industries.

VI. Recommendation

I recommend that from all process variables forging temperature and thermal

occurrences during the process are most complex and most important. For

achieving optimal manufacturing condition, reliable tool function and good

dimensional accuracy constant die and forging temperatures are essential. In

particular it is important for dies with very narrow tolerances and small gaps

between moving elements’ being any deviation of the die temperature causes

thermal expansion or shrinking of the tool elements. It can led to significant

dimensional changes of forgings and tool malfunction. Further, forging

temperature is directly responsible for the thermal shrinking of the forging parts,

microstructure of the final components, the flow stress, the material formability

etc. and consequently influences their quality and accuracy. In warm and hot

forging workpiece temperature must be carefully controlled at the exit of heating

device. Higher forging temperature reduces strain-hardening, elastic deformation

of tool and machine elements, it cause increase of die wear and scale formation.

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Uniform temperature gradient over the workpiece is preferred as it contributes

uniform shrinking of forged pars during cooling. Though process of cold forging

is usually preformed at room temperature, heat generated during forming process

can increase the temperature of workpiece and tool set for a few hundred degrees.

Having this in mind it is clear that when designing precision cold forging process

thermal effects have to be considered and appropriate corrections in tool

geometry preformed. To avoid thermal changes in cold forging, special attention

has to be paid to lubrication.

VII. Documentation

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VIII. Reference

https://en.wikipedia.org/wiki/Forging

https://www.quora.com/What-is-the-industrial-application-of-forging

http://www.mech4study.com/2017/04/what-is-forging-process-operation-

types-application-advantages-and-disadvantages.html

https://pdfs.semanticscholar.org/980d/f0ef73d23824d3aed9d41381d794c

1de830d.pdf