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A STUDY ON MANUFACTURING PROCESS OF FORGED COMPONENT [TITANIUM RING] A MINI PROJECT WORK IN THE PARTIAL FULFILLMENT OF THE DEGREE BACHELOR OF TECHNOLOGY IN MECHANICAL ENGINEERING BY S. SAMBHU PRAKASH (07241A03B1) K. KRISHNA CHAITANYA (07241A0390) K. VAMSI KRISHNA (07241A03B9) P. YASHWANTH KUMAR (07241A0372) Under the guidance of Prof. Dr. KURMA RAO & Mr. K.VENKAT RAO Prof. ADAPA RAMA RAO (Prod. manager, M.M.B. Pvt. Ltd) (Sr. professor) (External guide) (Internal guide) DEPARTMENT OF MECHANICAL ENGINEERING G.R.I.E.T (AFFILIATED TO J.N.T.U, HYDERABAD) 1

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  • A STUDY ON MANUFACTURING PROCESS OF

    FORGED COMPONENT

    [TITANIUM RING]

    A MINI PROJECT WORK IN THE PARTIAL FULFILLMENT OF THE DEGREE

    BACHELOR OF TECHNOLOGY IN

    MECHANICAL ENGINEERING

    BY

    S. SAMBHU PRAKASH (07241A03B1)

    K. KRISHNA CHAITANYA (07241A0390)

    K. VAMSI KRISHNA (07241A03B9)

    P. YASHWANTH KUMAR (07241A0372)

    Under the guidance of

    Prof. Dr. KURMA RAO & Mr. K.VENKAT RAO

    Prof. ADAPA RAMA RAO (Prod. manager, M.M.B. Pvt. Ltd)

    (Sr. professor) (External guide)

    (Internal guide)

    DEPARTMENT OF MECHANICAL ENGINEERING

    G.R.I.E.T

    (AFFILIATED TO J.N.T.U, HYDERABAD)

    1

  • ABSTRACT:

    The basic concept of this project is manufacturing the titanium rings by using forging process and different equipments like pneumatic hammer forging machines, furnaces, saddles, dies etc. The use of forging is to reduce material wastage and manufacturing time, avoids complex machining operations and used for mass production.

    These rings are manufactured by various operations like up-setting punching, roll forging and flattening. The process includes heat treatment and proof machining also. Pneumatic forging hammers, hand tools like saddles, mandrels, punches, calipers and tongs will play prominent role in this process.

    The project entitled study on manufacturing process of a forged component. In this project we are studying the manufacturing processes of titanium rings by forging process, which are used in aircrafts, missile heads and other defense projects.

    We have undergone the project at MANJIRA MACHINE BUILDERS PVT.LTD. located at PATANCHERU.

    S. SAMBHU PRAKASH

    K. KRISHNA CHAITANYA

    K. VAMSI KRISHNA

    P. YASHWANTH KUMAR

    2

  • ACKNOWLEDGEMENT:

    With immense pleasure we take this opportunity to thank all who have helped us in making project possible.

    We express our deep sense of gratitude and indebtedness to Sri. Dr. KURMA RAO, Sr.Professor of the Mechanical Engineering Dept, for his guidance, motivation, encouragement and timely help throughout the period of the project report in the systematic manner.

    We extend our whole hearted thanks to Dr. ADAPA RAMA RAO, Sr. professor in our department for granting the permission to carry out our project work.

    We also extend our whole hearted and grateful thanks to Mr. K. VENKAT RAO, production manager, MANJIRA MACHINE BUILDERS PVT.LTD, Hyderabad, for his patience, advice and technical guidance given during our project.

    S. SAMBHU PRAKASH

    K. KRISHNA CHAITANYA

    K. VAMSI KRISHNA

    P. YASHWANTH KUMAR

    3

  • DEPARTMENT OF MECHANICAL ENGINEERING

    G.R.I.E.T

    (Affiliated to Jawaharlal Nehru Technological University, Hyderabad)

    CERTIFICATE

    This is to certify that the mini project report entitled A STUDY ON MANUFACTURING PROCESS OF FORGED COMPONENT [ TITANIUM RING ] carried out at the end of III B .Tech, II semester is being submitted by the following students in partial fulfillment of the degree of BACHELOR OF TECHNOLOGY IN MECHANICAL ENGINEERING by the JAWAHARLAL NEHRU TECHNOLOGICAL UNIVERSITY , during the academic year 2010-11

    S. SAMBHU PRAKASH (07241A03B1)

    K. KRISHNA CHAITANYA (07241A0390)

    K. VAMSI KRISHNA (07241A03B9)

    P. YASHWANTH KUMAR (07241A0372)

    The results and information embodied into his mini project report have not been submitted to any other university or institution for the award of any degree or diploma.

    Prof. Dr. ADAPA RAMA RAO Prof. Dr. KURMA RAO

    (Sr. professor) (Sr. professor)

    (Internal guide) (Internal guide)

    4

  • ORGANIZATIONAL PROFILE:

    MANJIRA MACHINE BUILDERS.PVT.LTD is situated at Patancheru, Medak district. Its main products are manufacturing of cold rolling mills, hot rolling slitters, cold rolling slitters, cut to lengths, pickling lines and manufacture of quality forgings.

    MANJIRA also engaged with another organization called MANJIRA TECHNICAL SERVICES. There are around 150 members working in M.M.B.PVT.LTD. There is a beautiful garden maintained over the land for greenery.

    Main products of the factory are:

    1) Forging

    2) Manufacturing of cold rolling mills and processing machinery.

    Cold rolling mills.

    Hot rolling slitters.

    Cold rolling slitters.

    Cut to lengths.

    Pickling lines and manufacture of quality forgings.

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  • INDEX

    S.NO TOPIC PAGE: NO

    1.0 Introduction 9

    2.0 Common forging processes 11

    2.1 Forging temperatures

    2.2 Hand forging

    2.3 Press forging

    3.0 Forging operations 18

    3.1 Up-setting

    3.2 Roll-forging

    4.0 Materials used in forging 20

    5.0 Furnaces required in forging 22

    5.1 Continuous furnaces

    5.2 Box type furnaces

    5.3 Oil furnace

    5.4 Pit furnace

    6.0 Manufacturing process of forged component 27

    7.0 Advantages & Disadvantages 28

    8.0 Safety precautions 29

    9.0 Conclusion 30

    6

  • 10.0 Bibliography 31

    EQUIPMENT USED IN THE MANUFACTURING OF THE COMPONENT:

    750kg Pneumatic hammer.

    1500kg Pneumatic hammer.

    Small oil furnaces.

    Electric heating pit furnaces.

    Ultrasonic testing machine.

    Dynamic hardness testing machine.

    Brinell hardness testing machine.

    Poldi hardness tester.

    Temperature recorders and indicators.

    Temperature calibrator.

    Metallurgical microscope.

    7

  • HISTORY:

    Forging is one of the oldest known metalworking processes.

    Traditionally, forging was performed by a smith using hammer and anvil, and though the use of water power in the production and working of iron dates to the 12th century, the hammer and anvil are not obsolete. The smithy or forge has evolved over centuries to become a facility with engineered processes, production equipment, tooling, raw materials and products to meet the demands of modern industry. In modern times, industrial forging is done either with presses or with hammers powered by compressed air, electricity, hydraulics or steam. These hammers may have reciprocating weights in the thousands of pounds. Smaller power hammers, 500 lb (230 kg) or less reciprocating weight, and hydraulic presses are common in art smithies as well. Some steam hammers remain in use, but they became obsolete with the availability of the other, more convenient, power sources

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  • 1.0 INTRODUCTION:

    Forging is the process by which metal is heated and is shaped by plastic deformation by suitably applying compressive force. Usually the compressive force is in the form of hammer blows using a power hammer or a press.

    Forging refines the grain structure and improves the physical properties of the metal. With proper design, the grain flow can be oriented in the direction of principal stresses encountered in actual use. Grain flow is the direction of the pattern that the crystals take during plastic deformation. Physical properties (such as strength, ductility and toughness) are much better in a forging than in the base metal, which has, crystals randomly oriented.

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  • Forgings are consistent from piece to piece, without any of the porosity, voids, inclusions and other defects. Thus, finishing operations such as machining do not expose voids, because there aren't any. Also coating operations such as plating or painting are straightforward due to a good surface, which needs very little preparation.

    Forgings yield parts that have high strength to weight ratio-thus are often used in the design of aircraft frame members.

    A Forged metal can result in the following :

    1) Increase length, decrease cross-section, called drawing out the metal.

    2) Decrease length, increase cross-section, called upsetting the metal.

    3) Change length, change cross-section, by squeezing in closed impression dies. This results in favorable grain flow for strong parts

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  • 2.0 COMMON FORGING PROCESSES:

    The metal can be forged hot (above recrystallization temperatures) or cold.

    Open Die Forgings / Hand Forgings: Open die forgings or hand forgings are made with repeated blows in an open die, where the operator manipulates the work piece in the die. The finished product is a rough approximation of the die. This is what a traditional blacksmith does, and is an old manufacturing process.

    Impression Die Forgings / Precision Forgings: Impression die forgings and precision forgings are further refinements of the blocker forgings. The finished part more closely resembles the die impression.

    Design Consideration:

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  • Parting surface should be along a single plane if possible, else following the contour of the part. The parting surface should be through the center of the part, not near the upper or lower edges. If the parting line cannot be on a single plane, then it is good practice to use symmetry of the design to minimize the side thrust forces. Any point on the parting surface should be less than 75 from the principal parting plane.

    As in most forming processes, use of undercuts should be avoided, as these will make the removal of the part difficult, if not impossible.

    Recommended draft angles are described in the following table.

    Material Draft Angle ()

    Aluminum 0 - 2

    Copper Alloys (Brass) 0 - 3

    Steel 5 - 7

    Stainless Steel 5 - 8

    Generous fillets and radius should be provided to aid in material flow during the forging process. Sharp corners are stress-risers in the forgings, as well as make the dies weak in service. Recommended minimum radiuses are described in the following table.

    Height of Protrusionmm (in)

    Min. Corner Radiusmm (in)

    Min. Fillet Radius mm (in)

    12.5 (0.5)

    1.5 (0.06)

    5 (0.2)

    12

  • 25 (1.0)

    3 (0.12)

    6.25 (0.25)

    50 (2.0)

    5 (0.2)

    10 (0.4)

    100 (4.0)

    6.25 (0.25)

    10 (0.4)

    400 (16)

    22 (0.875)

    50 (2.0)

    Ribs should not be high or narrow; this makes it difficult for the material to flow.

    2.1 FORGING TEMPERATURES:

    Forging temperature is a temperature at which a metal becomes soft like clay or its shape can be changed by applying a relatively small force without creating cracks in metal.

    Note: Temperatures for alloys (combination of metals) will lie between the temperatures specified for the metals utilized.

    Chart for forging Temperature:

    13

  • 2.2 Hand forging:

    Material Celsius Fahrenheit

    Carbonsteel 1230 2246

    Stainlesssteel(Magnetic) 1095 2003

    Stainlesssteel(Nonmagnetic) 1150 2102

    Nickel 1095 2003

    Titanium 955 1751

    Copper 900 1652

    Brass(25AlloyTypesUtilizingDifferentRatios:Copper&Zinc) 815 1499

    Commercialbronze(90%copperand10%zinc) 900to419.53 1652to787.154

    Aluminum 540 1004

    Iron or steel heated and hammered to shape without the use of "closed dies". Drop forging uses "closed dies". Other than moving the piece from one cavity to the next there is no human input to the shape of the finished piece, the dies do it. Hand forging involves hammering the heated metal on an anvil - the movement of the material and the finished form are determined by the smith as the material is moved under the hammer. Each piece is slightly different. If you find "Hand Forged" and a barcode on plastic packaging is suspicious.

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  • Tools used in hand forging :

    1. Anvil

    2. Swage block

    3. Tongs

    4. Hammers

    5. Chisel

    6. Fullers

    7. Flatters

    8. Punches

    9. Drifts.

    Ball pane hammer Straight pane sledge hammer

    15

  • Twist hammer Bush hammer

    Sledge hammer Dog-head hammer

    2.3 Press forging:

    Press forging works slowly by applying continuous pressure or force, which differs from the near-instantaneous impact of drop-hammer forging. The amount of time the dies are in contact with the work piece is measured in seconds (as compared to the milliseconds of drop-hammer forges). The press forging operation can be done either cold or hot.

    The main advantage of press forging, as compared to drop-hammer forging, is its ability to deform the complete work piece. Drop-hammer forging usually only deforms the surfaces of the work piece in contact with the hammer and anvil; the interior of the work piece will stay relatively

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  • undeformed. Another advantage to the process includes the knowledge of the new parts strain rate. We specifically know what kind of strain can be put on the part, because the compression rate of the press forging operation is controlled.

    Press forging can be used to perform all types of forging, including open-die and impression-die forging. Impression-die press forging usually requires less draft than drop forging and has better dimensional accuracy. Also, press forgings can often be done in one closing of the dies, allowing for easy automation.

    Tools used in press forging:

    1. Swages

    2. Hot cutters

    3. Tongs

    4. Pinch-bars

    5. Spreaders

    6. Charging bars

    17

  • Tongs Chisel

    Fullering tool Swage

    3.0 Forging Operations:

    Some of the forging operations are as follows:

    1. Up setting 2. Roll forging 3. Piercing 4. Flattening 5. Drawing 6. Shaping

    18

  • 3.1 Upset forging:

    Upset forging increases the diameter of the work piece by compressing its length. Based on number of pieces produced this is the most widely used forging process. A few examples of common parts produced using the upset forging process are engine valves, couplings, bolts, screws, and other fasteners.

    3.2 Roll forging:

    Roll forging is a process where round or flat bar stock is reduced in thickness and increased in length. Roll forging is performed using two cylindrical or semi-cylindrical rolls, each containing one or more shaped grooves. A heated bar is inserted into the rolls and when it hits a stop the rolls rotate and the bar is progressively shaped as it is rolled out of the machine. The work piece is then transferred to the next set of grooves or turned around and reinserted into the same grooves. This continues until the desired shape and size is achieved. The advantage

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  • of this process is there is no flash and it imparts a favorable grain structure into the work piece.

    Examples of products produced using this method include axles, tapered levers and leaf springs.

    4.0 MATERIALS USED IN FORGING:

    Mostly in forging, Ferrous & Non-Ferrous metals are used in manufacturing purpose.

    Ferrous metals:

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  • These contain iron as a main constituent. These are stronger. Some of them are low and medium carbon steels, alloy steels, stainless steels, titanium, die-steels.

    Non-Ferrous metals: Non-ferrous metals do not contain iron as the main constituent. Generally they are weaker than ferrous metals but have other important properties such as corrosion resistance, high electrical and thermal conductivity, good formability and special electrical & magnetic properties the chief non-ferrous metals used in the industrial purpose are copper, aluminum, zinc, lead, tin, magnesium and their alloys.

    S.NO FERROUS METAL FORGING TEMP, IN C

    1. Low carbon steel 1250

    2. Medium carbon steel 850-1100

    3. Stainless steel 1200

    21

  • S.NO NON-FERROUS

    METALS

    FORGING TEMP

    IN C

    1. Brass 650-800

    2. Bronze 825-900

    3. Aluminum alloys 350-450

    5.0 FURNACES REQUIRED IN FORGING:

    Various types of heating furnaces (Oil or Pit) are widely used in forging for mass production. These furnaces are located near forging presses or hammers for convenient handling of the work. The furnace used in forging should be large enough to allow proper combustion of fuel and uniform distribution of heat.

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  • The following furnaces are mostly used in forging:

    Continuous furnaces Box type furnaces Oil furnace Pit furnace

    5.1 CONTINUOUS FURNACES:

    A comprehensive range of Continuous Mesh Belt Conveyor Type Hardening and Tempering Line Furnace for Fasteners that is used for various heat treatment applications in varied industries. These are manufactured using high grade raw material that is sourced from reliable vendors of the market. These furnaces are equipped with all the modernized and sophisticated units that are precisely designed by our team of experienced professionals.

    Specifications:

    Atmosphere: Methanol and LPG

    Capacity: 200, 400 and 1000 kg/hr

    Features:

    Ceramic fiber module lining

    Geared motor for driving the conveyor

    Control system to meet customer application

    23

  • Thyristor & PID controller for temperature uniformity

    Fans for temperature uniformity.

    5.2 BOX TYPE FURNACES:

    A quality range of Box Type Furnace that is insulated with high quality refractory bricks so as to minimize the heat. These furnaces are known for their temperature control accuracy and quality of the insulation that ensure maximum performance and efficiency. Further, rapid combustion is maintained by the current of air under pressure.

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  • Specifications:

    Application: Forging for max 1300 0C

    Capacity: 100 tons / batch

    Heating medium: Oil / gas

    5.3 OIL FURNACE:

    This is dual fuel furnace used for annealing or for doing any other processing. The burner used is of fully automatic fuel efficient. The furnace is fully lined with ceramic fixer for fuel efficiency and less heat leakage.

    25

  • 5.4 Pit furnace:

    This furnace is widely used for heating non-ferrous metals. Pit type batch furnace is mainly used for heavy and large parts. This furnace is generally heated up electrically and essentially a cylindrical refractory chamber. It is called Pit furnace, because most of its portion lies below the

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  • ground level.

    6.0 MANUFACTURING PROCESS OF FORGED COMPONENT:

    [ Non-ferrous metal, TITANIUM RING ]

    The following steps are involved in the manufacturing process of a forged component [TITANIUM RING which is a non-ferrous metal].

    Height 625mm

    Round 500mm

    Temp. Range 0-600 C

    Coil Coil dia - 14mm

    Wire dia - 2mm

    Length of coil 4600mm

    27

  • They are as follows:

    1. Raw material procurement

    2. Chemical analysis [ counter check ]

    3. Cutting the raw material

    4. Arrange the material into furnace

    5. Required operations

    Up-setting Punching Roll forging Flattening

    6. Heat treatment process

    7. Hardness checking

    8. Proof machining

    9. Ultrasonic test

    10. Dispatch

    Manufacturing Process: Forging Process Flow Chart:

    28

  • Machining Process Flow Chart:

    29

  • 7.0 ADVANTAGES & DISADVANTAGES:

    Advantages: 9 More uniform structure with directional characteristics.

    9 Minimum cavities and blow holes.

    9 High mechanical strength and toughness.

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  • 9 Smooth surface, closers dimensions permitting less machining.

    9 Economy in mass production.

    Disadvantages: 9 Size is limited

    9 Not suitable for complicated shapes.

    9 Tools and equipment cost in high.

    9 Process is not economical for small quantities.

    8.0 SAFETY PRECAUTIONS:

    In order to ensure safety during work and reduce industrial accidents to a minimum, it is necessary:

    9 To organize the production processes properly.

    9 To organize each working place rationally.

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  • 9 To observe strictly all labour safety laws and all safety engineering rules and regulations during work.

    9.0 CONCLUSION:

    The Titanium ring is made useful product or component using an appropriate method of operation to the need. The components are made by following the above said operation of forging using the tools. The components so made are used in aircraft and missile heads.

    The process of forging is so simple that unskilled labour can do the job easily without inconvenience. Accuracy cannot be obtained in forging. The forged components made by using pneumatic hammer machine have high rigidly and strength.

    Hence the component made by using pneumatic forging has demand and quality assurance.

    By this project, we could learn the various sequence of operations involved in forging component, we have about learn the applications of the tools in forging of a component.

    10.0 BIBLIOGRAPHY:

    9 WWW.WIKIPEDIA.ORG

    9 WORK SHOP TECHNOLOGY BY O.P. KHANNA

    9 METALLURGY AND MATERIAL SCIENCE BY EVINER

    9 NOTES FROM MANJIRA MACHINE BUILDERS PVT.LTD.

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