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    Forging Presentation

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    Rakesh Puri
    Forging is an ancient metalworking process traditionally done by blacksmiths that is now often industrialized. It involves shaping heated metal using hammers or presses. Forging produces parts that are stronger than cast or machined parts due to the internal grain structure being reshaped to follow the part form. The quality of the starting ingot and proper heating above the recrystallization temperature are important to eliminate defects and achieve the desired forged microstructure and properties. Parts are checked against specifications using tests and inspections like hardness measurements, dimensions, and non-destructive testing.

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    Forging Presentation

    Uploaded by

    Rakesh Puri
    103 views17 pages
    Forging is an ancient metalworking process traditionally done by blacksmiths that is now often industrialized. It involves shaping heated metal using hammers or presses. Forging produces parts that are stronger than cast or machined parts due to the internal grain structure being reshaped to follow the part form. The quality of the starting ingot and proper heating above the recrystallization temperature are important to eliminate defects and achieve the desired forged microstructure and properties. Parts are checked against specifications using tests and inspections like hardness measurements, dimensions, and non-destructive testing.

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    Forging is an ancient metalworking process traditionally done by blacksmiths that is now often industrialized. It involves shaping heated metal using hammers or presses. Forging produces parts that are stronger than cast or machined parts due to the internal grain structure being reshaped to follow the part form. The quality of the starting ingot and proper heating above the recrystallization temperature are important to eliminate defects and achieve the desired forged microstructure and properties. Parts are checked against specifications using tests and inspections like hardness measurements, dimensions, and non-destructive testing.

    Copyright:

    © All Rights Reserved
    Download as PPTX, PDF, TXT or read online from Scribd
    Download as pptx, pdf, or txt
    103 views17 pages

    Forging Presentation

    Uploaded by

    Rakesh Puri
    Forging is an ancient metalworking process traditionally done by blacksmiths that is now often industrialized. It involves shaping heated metal using hammers or presses. Forging produces parts that are stronger than cast or machined parts due to the internal grain structure being reshaped to follow the part form. The quality of the starting ingot and proper heating above the recrystallization temperature are important to eliminate defects and achieve the desired forged microstructure and properties. Parts are checked against specifications using tests and inspections like hardness measurements, dimensions, and non-destructive testing.

    Copyright:

    © All Rights Reserved
    Download as PPTX, PDF, TXT or read online from Scribd
    Download as pptx, pdf, or txt
    of 17

    FORGING

    Forging is one of the oldest known metal working process,


    traditionally performed by blacksmith. In modern times
    industrial forging is done either with hammers or Mechanical
    presses powered by compressed air, steam, electrically or
    hydraulic
    HAMMERS TYPE
     Hammers are classified according to its Ram
    weight/max blow energy/Nos. of blow per
    minute and ranged from 45kgs – 10 MT and
    power drop hammers goes up to 30MT. Presses
    are designed up to 16000MT.
    Drop Hammer with constant striking force
    Electro Hydraulic air/steam drop Hammer
    Hydraulic Press
    PROCESS
     Forging can produce a piece that is stronger than
    an eq. cast or Mechanical part due to its internal
    grain texture deforms to follow the general shape
    of the part.
    In general to understand forging we can divide the
    forging process as
    Drawn out: length increase , cross section decrease
    Upset : length increase , cross section decrease
    Squeezed: in close die, producing multidirectional flow
    Punching : Piercing hole
    INGOT
     Quality of ingot & its uniform heating up to
    core is essential to eliminates central porosity,
    dendritic structure, segregation from ingot
    during forging process. Ingot/cast/heat can be
    produced from Induction/BOF/electric/VD
    etc.

    Ingot Heating Temperature
     For forging out put we need
    Ingots/blooms/billet as noted in last slide to
    be heated in the heating furnace above
    recrystallization temperature and heating shall
    be good enough to produce finish forging well
    above transformation temp. Temp. ref. for
    carbon steel is as follows
    Carbon % 0.2 0.3 0.4 0.5
    Temp. 1275 1260 1245 1230
    degree
    centigrade
    Hot work ratio/ Reduction
     A ratio measuring change in the cross sectional
    area during hot forging process. The total hot
    reduction is define as a product of individual
    reduction ratio achieved at each forging step
    from ingot cross section to final forging size.
     Hot Upsetting is used as a meaning of
    preparing stock for forging on hammer/press
    and occasionally used as finishing operation
    following hammer or press forging.
     Reduction ration 1:4( min) recommended
    Conversion of ingot stock to forging
     Shaft
    Step forging
    Gear blank
    Saddles used for ring forgings
    Ring forging
    Forging control/check
     Selection and Quality of ingot
     Heating of ingot above recrystallization temperature.
     Conversion of ingot to final shape achieving desired result
    converting cast structure to sound forged one. (recommended
    reduction 1:4 (minimum)).
     Heat treatment (N, N+T, A, Q+T, S. R.) of forging as per
    requirement to achieved mechanical properties. Skin cut prior
    to HT is also recommended some time.
     TPM (Test piece marking)_Batch selection ,Sample location,
    orientation , TTC review, hardness review, stamping for ID
    and traceability on TPM and forged products as per
    respective standard/QAP (e.g. EN 10250-1,EN10083-
    1,EN10222-1,EN10028-1
    Testing and evaluation of Sample as per respective standard

    e.g.
     EN10002-1(tensile)
     EN10045-1(Impact)
     ISO 643 (Micro graphic)
     EN10247/DIN 50602(Non Metallic inclusion)
    (IS4163/ASTM E45)
     ISO6506-1/ISO6508 (HARDNESS)
    Testing and Evaluation of Forging product

     NDT (Ultrasonic, MPT,DPT) for checking


    product soundness as per respective standard
    and severity level (e.g. EN10228)
     Product hardness to match/close to (TPM)Test
    piece hardness
     Dimension
     Marking and Stamping
     Inspection record/Mfg. work certificate (EN
    10204)

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