1

REPORT

ON

CONVERSION OF INVESTMENT CASTING COMPONENTS TO FORGING

Submitted To- Submitted By- VINEET MAHAJAN ANANT SINGHAsst. Manager MECHANICAL Engg.A.D.D IIMT, Meerut

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ACKNOWLEDGEMENT

This training would not have been useful to me without the utmost support and

guidance from many people in the, Auxiliary and Development Department of TATA

MOTORS LTD.

Firstly, I would like to thank Mr. NAVNIT MALHOTRA (AGM) who helped me

throughout the training by sharing his knowledge and lots of experience he

possesses, weathered over the years in the automotive industry, it was indeed very

precious working under him.

Also, I appreciate the guidance provided to me by Mr. VINEET MAHAJAN (Asst.

Manager, ADD) who with his inspiring & innovative ideas, in a way, showed me the

path to enlighten myself in order to increase the capacity to do work.

I am grateful to Mr. Brijlal Arora (HR- Training cordinator) for letting me go through

the training, & making it altogether a diverse experience.

Last but not the least, I would like to thank the entire group of TATA MOTORS LTD. -

Pantnagar Plant, who helped me in every sphere they could, and didn’t even let me

gauge how long or short this period can be.

INDEX

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S. No. Page No.

Acknowledgement 2

1. World and Automobile 4

2. India and Automobile 5

3. Tata Group of Companies 7

4. Tata Motors Ltd. 8

5. Area of Business 9

6. Joint ventures, Subsidiaries and Associates 9

7. Research and Development 10

8. Location 11

9. Tata motors Hierarchy 12

10. Tata Motors Pantnagar 14

11. S.I.P 15

12. Introduction 16

13. Investment Cating 17

14. Forging 18

15. Types of Forging 20

16. Investment Casting conversion and comparison. 27

17. Investment Casting Vs. Forging 27

18. Scope. 28

19. Engg. Process. 28

20. Control Plan 29

21. F.M.E.A 35

22. P.P.A.P 39

23. Learning at TATA-MOTORS. 39

24. Bibliography. 40

1) World & Automobile

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During the 1670s, Father Ferdinand Verbiest (Flemish Jesuit missionary, China) designed the first ever self-propelled vehicle – many claim this as the world's first automobile but lack of evidence that it was actually built, in spite of its small size it could only operate for 12-15 minutes before running out of steam, and its tremendous weight and poor balance made it very difficult to steer

The first car was built by Joseph Cugnot in 1769. It was powered by a steam engine and was very slow.

Notable Personalities of Past :

1 cylinder IC engine J.J. Étienne Lenoir

4 cylinder IC engine N. August Otto

1st 4-wheel automobile & v-slanted engine

Gottlieb Daimler (1886)

Automobile powered by IC engine Karl Benz

Over 15 million Model Ts by 1927 Henry Ford

Hybrid cars Since the 1900’s.

1st hybrid commercial truck in 1910

2) India & Automobile

Automobile:o Public Transporto Personal Transport

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o War-fareo Law and ordero Tradeo Emergency Serviceso Public Hygiene o Sea Transporto Aero planes

Indian Automobile has 12 % share in Indian economy

AUTOMOBILE COMPANIES making the Dream Machines in India:

The forecast of various type of 4-wheelers production in India:

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GRAPH 2 GRAPH 3

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Commercial VehiclesPassenger Vehicles

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3) TATA GROUP OF COMPANIES

Tata Group, an Indian multinational conglomerate company, headquartered in the Bombay House in Mumbai, India, in terms of market capitalization and revenues, it is the largest private corporate group in India.

The Tata Group comprises 114 companies and subsidiaries in eight business sectors, 27 of which are publicly listed. 65.8% of the ownership of Tata Group is held in charitable trusts. The group takes the name of its founder, Jamsedji Tata, a member of whose family has almost invariably been the chairman of the group. The current chairman of the Tata group is Ratan Tata.

The Tata Group has operations in more than 80 countries across six continents and its companies export products and services to 80 nations.

TATA Group's 114 companies are held by its main Company Tata Sons. The 2009 annual survey included 600 global companies by the Reputation Institute ranked Tata Group as the 11th most reputable company in the world.

TATA GROUP of COMPANIES

Information technologies

• CMC • Computational

Research Labs • Nelito Systems • Tata Advanced

Systems • Tata Business

Support Services

• T ata Consultancy Services

• Tata Elxsi • Tata Interactive

Systems • Tata

Technologies • Comunication• Tata

Communication• Tata

Teleservices

• Tata sky• Tata Net• Nelco

• Automotive• Hispano

Carrocera • Jaguar Land

Rover • Tata AutoComp

Systems • Tata Cummins • Tata Daewoo

Commercial Vehicle Company

• Tata Motors • Tata Motors

European Technical Centre

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• Telco Construction Equipments

• Engineering• TAL

Manufacturing Solutions

• Tata Consulting Engineers

• Tata Projects • TRF• Voltas

• Metals• Hooghly Met

Coke & Power• JAMIPOL • Jamshedpur

Utilities and Services

• Mjunction services

• NatSteel Holdings

• Tata BlueScope Steel

• Tata Metaliks

• Tata Sponge Iron

• Tata Steel • Tata Steel KZN • Tata Steel

Processing and Distribution

• Tayo Rolls • The Tinplate

Company of India

• TM International Logistics

• Energy• North Delhi

Power • Powerliks

Transmission

• Tata BP Solar • Tata Petrodyne • Tata Power &

Tata Power Trading

• Consumer Product• Casa Decor • Infiniti Retail • Landmark • Tata Ceramics

• Tata Global Beverages

• Titan Industries • Trent • Westland

• Chemicals• Advinus

Therapeutics • Rallis India • Tata Chemicals • Tata Chemicals

Europe • Tata Chemicals

Magadi • Tata Chemicals

North America • Tata Pigments

• Other services• Drive India

Enterprise Solution

• Tata Industrial Services

• Tata Quality Management Services

• Tata Services • Tata Strategic

Management

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4) TATA MOTORS

Tata Motors Limited is a multinational automotive corporation. A part of the Tata Group, it was formerly known as TELCO (TATA Engineering and Locomotive Company).

Established in 1945 by J.R.D.Tata, Tata Motors' presence indeed cuts across the length and breadth of India. Tata Motors is India's largest automobile company, with consolidated revenues of Rs. 1, 23,133 crores ($ 27 billion) in 2010-11.

Through subsidiaries and associate companies, Tata Motors has operations in the UK, South Korea, Thailand and Spain. Among them is Jaguar Land Rover, the business comprising the two iconic British brands. It also distributes Fiat cars in India, and has an industrial joint venture with Fiat in India. With over 5.9 million Tata vehicles plying in India, Tata Motors is the country's market leader in commercial vehicles and among the top three in passenger vehicles. It is also the world's 4th largest truck manufacturer and 3rd largest bus manufacturer. Tata cars, buses and trucks are being marketed in several countries in Europe, Africa, the Middle East, South Asia, South East Asia and South America

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4a) Areas of business:  

Tata Motors makes passenger cars, multi-utility vehicles and light, medium and heavy commercial vehicles.

Passenger cars: compact Tata Indica in 1998, the sedan Indigo in 2002 and the station wagon Indigo Marina in 2004. Tata Motors also distributes Fiat’s cars in India.

Utility vehicles: The Tata Sumo was launched in 1994 and the Tata Safari in 1998.

Commercial vehicles: The commercial vehicle range extends from the light two-tonne truck to heavy dumpers and multi-axled vehicles in the above 40-tonne segment.

Passenger buses: The Company also manufactures and sells passenger buses, 12-seaters to 60-seaters, in the light, medium and heavy segments.

4b) JOINT VENTURES, SUBSIDIARIES, ASSOCIATES

Tata Motors has joint ventures with MARCOPOLO, the Brazil-based maker of bus and coach bodies, and with FIAT-AUTO (to build a commercial vehicle at Fiat's facilities in Córdoba, Argentina).Other associates include:

Tata Daewoo Commercial Vehicle Co.: heavy commercial vehicles

Tata Motors European Technical Centre: design engineering and development of products.

Telco Construction Equipment Company: construction equipment and allied services.

Tata Technologies: design services, product lifecycle management and product-centric IT services.

Tata Motors (Thailand): Tata Motors (70%) and Thonburi Automotive Assembly Plant Co (30%).

Tata Cummins: manufactures high horsepower engines.

HV Transmissions and HV Axles: make gearboxes and axles for commercial vehicles.

TAL Manufacturing Solutions: provides factory automation solutions and provides machine tools.

Hispano Carrocera: Spanish bus manufacturing company.

Concorde Motors: retailing Tata Motors’ range of passenger vehicles

Tata Motors Finance: the business of financing customers and channel partners of Tata Motors

4c) Research & Development

The company’s Engineering Research Centre (ERC), in Pune (which

has 1400 scientists and engineers), Tata Daewoo Commercial Vehicle Company Hispano Carrocera at Gunsan in Korea and Zaragoza

in Spain.

These three facilities together enable the company to share and access knowledge and technology for designing and developing world-class products which are environment-friendly technologies in emissions and alternative fuels.

It was Tata Motors, which developed the first indigenously developed Light Commercial

Vehicle, India’s first Sports Utility Vehicle Tata Indica, India’s first fully indigenous passenger

car (India’s largest selling car) Tata Ace, India’s first mini-truck.

The ERC in Pune, among whose facilities are India’s only certified crash-test facility and hemi-anechoic chamber for testing of noise and vibration has received several awards from the Government of India.

Some of the more prominent amongst them are:

National Award for Research and Development Efforts in Industry in the Mechanical Engineering Industries sector in 1999,

National Award for Successful Commercialization of Indigenous Technology by an Industrial Concern in 2000

CSIR Diamond Jubilee Technology Award in 2004.

Adopting the principle of Kaizen or continuous learning, versatile yet simple 5S approach to process improvement which helps to optimize various operations of the company and conserve precious resources is the way of life at Tata Motors.

The company introduced emission-friendly engines in its products in India even before such norms were made statutory. It ensures that its products are environmentally sound by reducing hazardous materials in vehicle components, developing extended life lubricants, fluids and using ozone-friendly refrigerants.

4d) Location

Tata Motors' plants are located at o Jamshedpur (eastern India),

o Pune and Sanand (western India),

o Lucknow and Pantnagar (northern India).

o Tata Motors and Fiat have a common manufacturing

facility at Ranjangaon, near Pune.

being marketed in several countries

Europe, Africa, Middle East,South East Asia, South Asia and Australia

assembly operations

Malaysia, Kenya, Bangladesh, Ukraine, Russia, Spain and Senegal..

4e) TATA Motors Hierarchy

Board of Directors

Mr. Ratan N. Tata (Chairman)

Mr. Ravi Kant Mr. Nusli N.

Wadia Mr. S. M. Palia Dr. R. A.

Mashelkar Mr. Nasser

Munjee

Mr. Subodh Bhargava

Mr. V. K. Jairath Mr. Ranendra

Sen Dr. Ralf Speth Mr. Carl-Peter

Forster Mr. P. M.

Telang

Senior Management

Mr. Carl-Peter Forster Managing Director & Group CEO

Mr. P. M. Telang Managing Director - India Operations

Mr. C. Ramakrishnan Chief Financial Officer

Mr. Ravi Pisharody President (CVBU)

Dr. Tim Leverton Head (Advanced and Product Engineering)

Mr. S. B. Borwankar Senior Vice President (Mfg Operations-CVBU)

Mr. Prabir Jha Senior Vice President (Human Resources)

Mr. R. Ramakrishnan Vice - President (Commercial - PCBU)

Mr. Girish Wagh Head (Passenger Car Operations - PCBU)

Mr. R. T. Wasan Head (International Business - CVBU)

Mr. Johnny Oommen Head (International Business - PCBU)

Mr. H. K. Sethna Company Secretary

FIG. 2: Fuel type- Diesel, Gasoline and CNG

4f) TATA MOTORS (Small Car Division) Pantnagar

This plant came into existence in 2007. TATA MOTORS LTD. Pant Nagar has four shops for manufacturing of vehicles.

DESCRIPTION OF SHOPS

ASSEMBLY SHOP –

Also known as TCF Shop(TRIM CHASSIS FITTING). In this shop all the assembly works like Engine,Suspension, Tyres, Lights, Dashboard etc. fitting is carried out.

WELD SHOP –

Also known as BIW Shop(BODY IN WHITE) .Here the different parts are welded together and the whole structure of the car is built.

POWER TRAIN SHOP –

o This shop is divided into Power Train and Engine shop. Here various operations related to Engine, Gear Trains etc. are performed.

PAINT SHOP –

The TAIKISHA paint shop is the beauty parlors of the car plant. This shop paints the car in various shades. It takes 18 steps spread over less than 10 hours to accomplish the task.

TATA MOTORS

CKD(COMPLETE KNOCK DOWN)BIW-1A

GEAR ASSEMBLY

BIW-1CBIW-1B

SUMMER INTERNSHIP PROJECT (SIP)ON

CONVERSION OF INVESTMENT CASTING COMPONENTS TO FORGING

INTRODUCTION

INPUTS

MAN MATERIAL MACHINE/TOOLING METHOD ENVRIONMENT

PROCESS

OUTPUT

Investment Castings

Featuring unlimited alloy choices, investment castings are the most versatile metal forming methods available. Designers are not limited to any particular alloy, as the investment casting process allows for easy alloy substitution using the same tooling.

Each alloy has unique mechanical properties, including varying degrees of hardness, corrosion resistance, electrical conductivity, and ductility. Visit each alloy page for real world examples of how Precision Castings of Tennessee is changing the investment casting industry.

Stainless Steel Castings

Can meet any surface finish without plating

Can be polished to a mirror finish

Ultimate in corrosion resistance

Bronze, Brass & Copper Castings

High fatigue resistance High ductility Non-corrosive Self-lubricating

Aluminium Castings

Stronger than steel pound for pound

High heat dispersion capabilities

Ideal for weight reduction

Cobalt &   Nickel Based Castings

High alloy steels and exotics Highest corrosion resistance Highest heat resistance

Steel Castings

Cost-effective Widest range of mechanical

properties Smooth surface finish without

grinding

Tool Steel Castings

Engineered for impact & edge based tools

High wear resistance High hardness levels

Ductile Iron   Castings

Impressive mechanical properties

Fatigue resistance More cost-effective than steel

Woodworking Metal Castings

High-impact toughness Design improvement

opportunities  Razor-sharp edges

FORGING

Forging is a manufacturing process involving the shaping of metal using localized compressive forces. Forging is often classified according to the temperature at which it is performed: "cold", "warm", or "hot" forging. Forged parts can range in weight from less than a kilogram to 580 metric tons.Forged parts usually require further processing to achieve a finished part.

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.

ADVANTAGES and DISADVANTAGES:

Forging can produce a piece that is stronger than an equivalent cast or machined part. As the metal is shaped during the forging process, its internal grain deforms to follow the general shape of the part. As a result, the grain is continuous throughout the part, giving rise to a piece with improved strength characteristics.

Some metals may be forged cold, but iron and steel are almost always hot forged. Hot forging prevents the work hardening that would result from cold forging, which would increase the difficulty of performing secondary machining operations on the piece. Also, while work hardening may be desirable in some circumstances, other methods of hardening the piece, such as heat treating, are generally more economical and more controllable. Alloys that are amenable to precipitation hardening, such as most aluminium alloys and titanium, can be hot forged, followed by hardening.[citation needed]

Production forging involves significant capital expenditure for machinery, tooling, facilities and personnel. In the case of hot forging, a high-temperature furnace (sometimes referred to as the forge) is required to heat ingots or billets. Owing to the massiveness of large forging hammers and presses and the parts they can produce, as well as the dangers inherent in working with hot metal, a special building is frequently required to house the operation. In the case of drop forging operations, provisions must be made to absorb the shock and vibration generated by the hammer. Most forging operations use metal-forming dies, which must be precisely machined and carefully heat-treated to correctly shape the workpiece, as well as to withstand the tremendous forces involved.

PROCESS:

There are many different kinds of forging processes available, however they can be grouped into three main classes.

Drawn out: length increases, cross-section decreases Upset: length decreases, cross-section increases Squeezed in closed compression dies: produces multidirectional flow

Common forging processes include: roll forging, swaging, cogging, open-die forging, impression-die forging, press forging, automatic hot forging and upsetting.

Temperature:

Main articles: Hot working and Cold working

All of the following forging processes can be performed at various temperatures, however they are generally classified by whether the metal temperature is above or below the recrystallization temperature. If the temperature is above the material's recrystallization

temperature it is deemed hot forging; if the temperature is below the material's recrystallization temperature but above 30% of the recrystallization temperature (on an absolute scale) it is deemed warm forging; if below 30% of the recrystallization temperature (usually room temperature) then it is deemed cold forging. The main advantage of hot forging is that as the metal is deformed work

hardening effects are negated by the recrystallization process. Cold forging typically results in work hardening of the piece.

TYPES:

Drop forging:

Drop forging is a forging process where a hammer is raised up and then "dropped" onto the workpiece to deform it according to the shape of the die. There are two types of drop forging: open-die drop forging and closed-die drop forging. As the names imply, the difference is in the shape of the die, with the former not fully enclosing the workpiece, while the latter does.

Open-die drop forging:

Open-die forging is also known as smith forging.In open-die forging, a hammer strikes and deforms the workpiece, which is placed on a stationary anvil. Open-die forging gets its name from the fact that the dies (the surfaces that are in contact with the workpiece) do not enclose the workpiece, allowing it to flow except where contacted by the dies. Therefore the operator needs to orient and position the workpiece to get the desired shape. The dies are usually flat in shape, but some have a specially shaped surface for specialized operations. For example, a die may have a round, concave, or convex surface or be a tool to form holes or be a cut-off tool.

Open-die forging lends itself to short runs and is appropriate for art smithing and custom work. In some cases, open-die forging may be employed to rough-shape ingots to prepare them for subsequent operations. Open-die forging may also orient the grain to increase strength in the required direction.

Cogging is successive deformation of a bar along its length using an open-die drop forge. It is commonly used to work a piece of raw material to the proper thickness. Once the proper thickness is achieved the proper width is achieved via edging.[8] Edging is the process of concentrating material using a concave shaped open die. The process is called edging, because it is usually carried out on the ends of the workpiece. Fullering is a similar process that thins out sections of the forging using a convex shaped die. These processes prepare the workpieces for further forging processes.

Impression-die drop forging:

Impression-die forging is also called closed-die forging. In impression-die forging, the metal is placed in a die resembling a mold, which is attached to the anvil. Usually the hammer die is shaped as well. The hammer is then dropped on the workpiece, causing the metal to flow and fill the die cavities. The hammer is generally in contact with the workpiece on the scale of milliseconds. Depending on the size and complexity of the part the hammer may be dropped multiple times in quick succession. Excess metal is squeezed out of the die cavities, forming what is referred to as flash. The flash cools more rapidly than the rest of the material; this cool metal is stronger than the metal in the die so it helps prevent more flash from forming. This also forces the metal to completely fill the die cavity. After forging the flash is removed.

In commercial impression-die forging the workpiece is usually moved through a series of cavities in a die to get from an ingot to the final form. The first impression is used to distribute the metal into the rough shape in accordance to the needs of later cavities; this impression is called an edging, fullering, or bending impression. The following cavities are called blocking cavities, in which the piece is working into a shape that more closely resembles the final product. These stages usually impart the workpiece with generous bends and large fillets. The final shape is forged in a final or finisher impression cavity. If there is only a short run of parts to be done it may be more economical for the die to lack a final impression cavity and instead machine the final features.

Impression-die forging has been improved in recent years through increased automation which includes induction heating, mechanical feeding, positioning and manipulation, and the direct heat treatment of parts after forging.

One variation of impression-die forging is called flashless forging, or true closed-die forging. In this type of forging the die cavities are completely closed, which keeps the workpiece from forming flash. The major advantage to this process is that less metal is lost to flash. Flash can account for 20 to 45% of the starting material. The disadvantages of this process include additional cost due to a more complex die design and the need for better lubrication and workpiece placement.

There are other variations of part formation that integrate impression-die forging. One method incorporates casting a forging preform from liquid metal. The casting is removed after it has solidified, but while still hot. It is then finished in a single cavity die. The flash is trimmed, then the part is quench hardened. Another variation follows the same process as outlined above, except the preform is produced by the spraying deposition of metal droplet into shaped collectors (similar to the Osprey process).

Closed-die forging has a high initial cost due to the creation of dies and required design work to make working die cavities. However, it has low recurring costs for each part, thus forgings become more economical with more volume. This is one of the major reasons closed-die forgings are often used in the automotive and tool industry. Another reason forgings are common in these industrial

sectors is that forgings generally have about a 20 percent higher strength-to-weight ratio compared to cast or machined parts of the same material.

Design of impression-die forgings and tooling:

Forging dies are usually made of high-alloy or tool steel. Dies must be impact resistant, wear resistant, maintain strength at high temperatures, and have the ability to withstand cycles of rapid heating and cooling. In order to produce a better, more economical die the following rules should be followed:

The dies should part along a single, flat plane if at all possible. If not the parting plane should follow the contour of the part.

The parting surface should be a plane through the center of the forging and not near an upper or lower edge.

Adequate draft should be provided; a good guideline is at least 3° for aluminum and 5° to 7° for steel.

Generous fillets and radii should be used. Ribs should be low and wide. The various sections should be balanced to avoid extreme difference in

metal flow. Full advantage should be taken of fiber flow lines. Dimensional tolerances should not be closer than necessary.

The dimensional tolerances of a steel part produced using the impression-die forging method are outlined in the table below. The dimensions across the parting plane are affected by the closure of the dies, and are therefore dependent on die wear and the thickness of the final flash. Dimensions that are completely contained within a single die segment or half can be maintained at a significantly greater level of accuracy.

Dimensional tolerances for impression-die forgingsMass [kg (lb)] Minus tolerance [mm (in)] Plus tolerance [mm (in)]0.45 (1) 0.15 (0.006) 0.48 (0.018)0.91 (2) 0.20 (0.008) 0.61 (0.024)2.27 (5) 0.25 (0.010) 0.76 (0.030)4.54 (10) 0.28 (0.011) 0.84 (0.033)9.07 (20) 0.33 (0.013) 0.99 (0.039)22.68 (50) 0.48 (0.019) 1.45 (0.057)45.36 (100) 0.74 (0.029) 2.21 (0.087)

A lubricant is used when forging to reduce friction and wear. It is also used as a thermal barrier to restrict heat transfer from the workpiece to the die. Finally, the lubricant acts as a parting compound to prevent the part from sticking in the dies.

Press forging:

Press forging works by slowly applying a 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 workpiece 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 workpiece. Drop-hammer forging usually only deforms the surfaces of the workpiece in contact with the hammer and anvil; the interior of the workpiece will stay relatively undeformed. Another advantage to the process includes the knowledge of the new part's 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. There are a few disadvantages to this process, most stemming from the workpiece being in contact with the dies for such an extended period of time. The operation is a time-consuming process due to the amount and length of steps. The workpiece will cool faster because the dies are in contact with workpiece; the dies facilitate drastically more heat transfer than the surrounding atmosphere. As the workpiece cools it becomes stronger and less ductile, which may induce cracking if deformation continues. Therefore heated dies are usually used to reduce heat loss, promote surface flow, and enable the production of finer details and closer tolerances. The workpiece may also need to be reheated. When done in high productivity, press forging is more economical than hammer forging. The operation also creates closer tolerances. In hammer forging a lot of the work is absorbed by the machinery, when in press forging, the greater percentage of work is used in the work piece. Another advantage is that the operation can be used to create any size part because there is no limit to the size of the press forging machine. New press forging techniques have been able to create a higher degree of mechanical and orientation integrity. By the constraint of oxidation to the outer layers of the part, reduced levels of microcracking occur in the finished part.

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.

Upset forging:

Upset forging increases the diameter of the workpiece 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.

Upset forging is usually done in special high-speed machines called crank presses, but upsetting can also be done in a vertical crank press or a hydraulic press. The machines are usually set up to work in the horizontal plane, to facilitate the quick exchange of workpieces from one station to the next. The initial workpiece is usually wire or rod, but some machines can accept bars up to 25 cm (9.8 in) in diameter and a capacity of over 1000 tons. The standard upsetting machine employs split dies that contain multiple cavities. The dies open enough to allow the workpiece to move from one cavity to the next; the dies then close and the heading tool, or ram, then moves longitudinally against the bar, upsetting it into the cavity. If all of the cavities are utilized on every cycle

then a finished part will be produced with every cycle, which makes this process advantageous for mass production.

These rules must be followed when designing parts to be upset forged:

The length of unsupported metal that can be upset in one blow without injurious buckling should be limited to three times the diameter of the bar.

Lengths of stock greater than three times the diameter may be upset successfully provided that the diameter of the upset is not more than 1.5 times the diameter of the stock.

In an upset requiring stock length greater than three times the diameter of the stock, and where the diameter of the cavity is not more than 1.5 times the diameter of the stock, the length of unsupported metal beyond the face of the die must not exceed the diameter of the bar.

Automatic hot forging:

The automatic hot forging process involves feeding mill-length steel bars (typically 7 m (23 ft) long) into one end of the machine at room temperature and hot forged products emerge from the other end. This all occurs rapidly; small parts can be made at a rate of 180 parts per minute (ppm) and larger can be made at a rate of 90 ppm. The parts can be solid or hollow, round or symmetrical, up to 6 kg (13 lb), and up to 18 cm (7.1 in) in diameter. The main advantages to this process are its high output rate and ability to accept low-cost materials. Little labor is required to operate the machinery. There is no flash produced so material savings are between 20 and 30% over conventional forging. The final product is a consistent 1,050 °C (1,920 °F) so air cooling will result in a part that is still easily machinable (the advantage being the lack of annealing required after forging). Tolerances are usually ±0.3 mm (0.012 in), surfaces are clean, and draft angles are 0.5 to 1°. Tool life is nearly double that of conventional forging because contact times are on the order of 0.06 second. The downside is that this process is only feasible on smaller symmetric parts and cost; the initial investment can be over $10 million, so large quantities are required to justify this process.

The process starts by heating the bar to 1,200 to 1,300 °C (2,192 to 2,372 °F) in less than 60 seconds using high-power induction coils. It is then descaled with rollers, sheared into blanks, and transferred through several successive forming stages, during which it is upset, preformed, final forged, and pierced (if necessary). This process can also be coupled with high-speed cold-forming operations. Generally, the cold forming operation will do the finishing stage so that the advantages of cold-working can be obtained, while maintaining the high speed of automatic hot forging.

Examples of parts made by this process are: wheel hub unit bearings, transmission gears, tapered roller bearing races, stainless steel coupling flanges, and neck rings for LP gas cylinders.Manual transmission gears are an example of automatic hot forging used in conjunction with cold working.

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 through the machine. The 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 of this process is there is no flash and it imparts a favorable grain structure into the workpiece.

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

Net-shape and near-net-shape forging.

Near-net-shape :

This process is also known as precision forging. It was developed to minimize cost and waste associated with post-forging operations. Therefore, the final product from a precision forging needs little or no final machining. Cost savings are gained from the use of less material, and thus less scrap, the overall decrease in energy used, and the reduction or elimination of machining. Precision forging also requires less of a draft, 1° to 0°. The downside of this process is its cost, therefore it is only implemented if significant cost reduction can be achieved.

Cost implications:

To achieve a low-cost net shape forging for demanding applications that are subject to a high degree of scrutiny, i.e. non-destructive testing by way of a dye-penetrant inspection technique, it is crucial that basic forging process disciplines be implemented. If the basic disciplines are not met, subsequent material removal operations will likely be necessary to remove material defects found at non-destructive testing inspection. Hence low-cost parts will not be achievable.

Example disciplines are: die-lubricant management (Use of uncontaminated and homogeneous mixtures, amount and placement of lubricant). Tight control of die temperatures and surface finish / friction.

Induction forging:

Unlike the above processes, induction forging is based on the type of heating style used. Many of the above processes can be used in conjunction with this heating method.

Equipment:

Hydraulic drop-hammer

(a) Material flow of a conventionally forged disc; (b) Material flow of an impactor forged disc

The most common type of forging equipment is the hammer and anvil. Principles behind the hammer and anvil are still used today in drop-hammer equipment. The principle behind the machine is simple: raise the hammer and drop it or propel it into the workpiece, which rests on the anvil. The main variations between drop-hammers are in the way the hammer is powered; the most common being air and steam hammers. Drop-hammers usually operate in a vertical position. The main reason for this is excess energy (energy that isn't used to deform the workpiece) that isn't released as heat or sound needs to be transmitted to the foundation. Moreover, a large machine base is needed to absorb the impacts.

To overcome some shortcomings of the drop-hammer, the counterblow machine or impactor is used. In a counterblow machine both the hammer and anvil move and the workpiece is held between them. Here excess energy becomes recoil. This allows the machine to work horizontally and have a smaller base. Other advantages include less noise, heat and vibration. It also produces a distinctly different flow pattern. Both of these machines can be used for open-die or closed-die forging.

Forging presses:

A forging press, often just called a press, is used for press forging. There are two main types:

mechanical and hydraulic presses. Mechanical presses function by using cams, cranks and/or toggles to produce a preset (a predetermined force at a certain location in the stroke) and reproducible stroke. Due to the nature of this type of system, different forces are available at different stroke positions. Mechanical presses are faster than their hydraulic counterparts (up to 50 strokes per minute). Their capacities range from 3 to 160 MN (300 to 18,000 short tons-force). Hydraulic presses use fluid pressure and a piston to generate force. The advantages of a hydraulic press over a mechanical press are its flexibility and greater capacity. The disadvantages include a slower, larger, and costlier machine to operate.The roll forging, upsetting, and automatic hot forging processes all use specialized machinery.

List of large forging presses, by ingot sizeForce

(tonnes)Ingot size(tonnes)

Company Location

16,000 600 China National Erzhong Group Deyang, China14,000 600 Japan Steel Works Japan15,000 580 China First Heavy Industries Group Heilongjiang, China

13,000 Doosan South Korea

Investment Casting Conversion & Comparison

“Saving money, one piece at a time”

Almost any metal part can be converted to an investment casting. Conversions generally allow for weight reduction opportunities, reduced machining, elimination of draft angles, and increased design flexibility. Castings can be converted into any alloy, allowing for virtually unlimited mechanical properties. 

Candidates for casting conversion include metal parts that are otherwise difficult or impossible to machine, castings with highly complex internal geometries, and expensive alloy types that produce extensive waste using other manufacturing methods.

List of large forging presses, by forceForce

(tonnes)Force(tons)

Ingot size(tonnes)

Company Location

80,000 (88,200) China Erzhong Deyang, China75,000 (82,690) VSMPO-AVISMA Russia65,000 (71,660) Aubert & Duval Issoire, France(45,350) 50,000 20 Alcoa, Wyman Gordon USA40,000 (44,100) Aubert & Duval Pamiers, France30,000 (33,080) 8 Wyman Gordon Livingston, Scotland

Depending on part complexity and desired production rate, investment casting is not always the best option. The following comparison guide can help you determine if investment casting conversion is right for you.

Investment Casting vs. Forging

Investment casting surface finishes eliminate forging parting lines and pitting

Investment castings offer uniform internal stresses Forging process causes directional stresses

Forging tooling is generally more expensive

Scope

Conversion of investment casting to forging:

Sl.No.

Features Investment Casting Forging

1.Vendors Limited Easily Available

2.Availability Out of state In state

3.Transportation Complex Easy

4. Excise Duty Apprx. 12.36% NIL

ENGINEERING PROCESS:

This process is processed by the particular vendors of Tata Motors Ltd. like

SANSERA ENGINEERING BAJAJ MOTORS

This process involves the following procedure:

Control Plan:What is a Control Plan ?

A summary of the system for controlling

variation of product characteristics.

process characteristics.

Contract between supplier and customer.

Summarizes the entire control strategy.

Objective:

TO PLANT

FORGING DRAWING

APL- FORGING DRAWING APPROVAL

FORGING

DIE MANUFACTURE

FORGING SAMPLEENDURANCE TEST

PLAN DROPPED

PROCESS APPROVED

Not OK KOK

OK

To ensure that a written plan for controlling all parts & processes is documented

Control Plan - An important phase in Quality Planning Process

Control Plan should include

All Operations listed on the process flow chart.

Machine Jig or Tooling.

Product and Process Characteristics.

Designated Special Characteristics.

Specifications or Tolerances.

Gauging or Evaluation Techniques.

Sample Size and Frequency.

Control Methods.

Reaction Instructions at each stage of production .

Information should be consistent with other documents such as

DFMEA, Process Flow, PFMEA

Control Plan can be grouped by commonality of

Parts.

Assemblies.

Features.

Design.

Processes.

Similar routing.

Similar level of complexity .

Control Plan is maintained and used throughout the product life cycle

Stages of Control plan

Prototype Control Plan

Pre-Launch Control Plan.

Production Control Plan.

Header Information: Prototype :

Developed for prototypes where majority of characteristics are 100 % inspected or tested.

Includes a description of measurement/tests that occur during prototype builds.

Use production process whenever possible.

Pre-launch or Pilot :

Description of measurements/tests before full production.

Most pre-launch should be under typical production condition.

Production :

Comprehension documentation.

Change in Size & Frequency.

Encompasses high volume production .

Operation Number :

Usually referenced from the Process Flow Chart.

If multiple part number exist (assembly), list the individual part numbers and their processes accordingly.

Process Name / Operation Description :

All steps in the manufacturing are described in Process Flow Diagram.

Identify the name that best describes the activity being addressed e.g. Drilling, Milling, Hobbing, Torque.

Machine, Device, Jigs & Tool Description :

Mention Machine No., Fixture / Jig No. & Tool No. that will be used during actual process.

Characteristics

A distinguishing feature, dimension or property of a process or its output (product) on which data (variable or attribute) can be collected.

Use visual aid where applicable.

Number :

A cross reference from all applicable documents Blue Prints, FMEAs etc.

Product Characteristics

Features or properties of a product that are described on drawings or primary engineering information.

Process Characteristics :

Process variables that have a cause and effect relationship with identified Product Characteristics.

Can be measure only at the time it occurs.

Team to identify these for which variation must be controlled to minimise product variation.

There could be more than one process characteristics for each characteristics.

Special Characteristics Classification

For identified Special characteristics through DFMEA & PFMEA to be put.

Appropriate symbols or Identification to be put e.g. <CC> or <SC>

For others characteristics to be left blank

Methods:

A systematic plan using procedures and other tools to control a process

• Product/Process Specification/Tolerance

• This include actual Product or Process Specification

• If Speed, Feed are process characteristics, CNC Programme No. reference can also be given.

• Evaluation Methods / Measurement Technique

Systems required to measure product and process characteristics

This could include gauges, fixtures, tools and or test equipment required to measure

Analysis of linearity, reproducibility, repeatability, stability and accuracy of the measurement system to be done,

A reasonable Gauge R & R must be attained

The acceptance criteria for GRR is 10 %

Sample Size/Frequency

Sampling Guideline: Use rational sampling plans

Sample should separate special causes from common causes

Based on a unit of production( e.g. parts, kg etc)

Event Driven ( at start of the shift, tool change etc.)

Control Method :

A brief description of how the operation would be controlled

Should be based on effective analysis of the process

Is determined by the type of process that exists

Types : SPC, inspection, sampling, mistake - proofing

If elaborate control procedure are used,

Reference of the procedure number

Method of control to be Continually evaluated for effectiveness of process control

Typical Entries in Control Method Table:

Quality Check Sheets or Inspection Sheets

Setup Approval, Operation Instructions etc.

PM Check Sheet

Process Parameter Logs

Tool Change Logs

Variable / Attribute Control Charts

These controls are generally used for all product characteristics regard less of importance ranking

Developing Control Methods For process control to be effective, a basic understanding of Process

Management is essential

Team should analyse sources of variation in the process

identify dominant factor to suitably decide controls

Reaction Plan:

It specifies what to do when:

a failure occurs

the process goes out of control

the process improves

The typical reactions are:

contain

investigate

record (good and bad incidences)

Reaction Plans are mechanisms for continuous improvement and standardisation

This column will typically contain reference to a detailed document

As a part of QS 9000 requirements, Control of Nonconforming Product require,

Identification, documentation, evaluation and segregation and disposition of nonconforming product

Some more Details: In support of control plan, process monitoring instructions should be

defined

Control Plan does not replace the information contained in detailed operator instructions

Sketches to be attached for better illustration

Control Plan is updated as measurement systems & control methods are evaluated & improved

Assessment of Control Plan for Quality of Event

A checklist for assessment of Control Plan is used

Prototype, Pre-launch, Production

The checklist basically mentions the activities expected to be done during the Control Plan.

While performing the assessment, assessor(s) should review each point by posing question, ‘has the expectation been met?’

It should be Rated as per the guideline

The minimum Overall Score Expected is ‘2’

Checklist can be used anytime

Benefits of Control Plan Provides a thorough evaluation of the product & process

Focus resources on characteristics that are important to customer

Identifies sources of variation in process which cause variation in product characteristics

It describes all actions to assure process would be state of control.

Control Plan Provides a structured approach for the design, selection and

implementation of value-added control methods for the total system.

FMEA

Where does FMEA come from? Developed by the Aerospace industry in the 1960s.

Spread to the Automotive industry.

Now used extensively across all industry sectors.

• Different Types of FMEA

• Design An analytical technique used primarily by Design.

Responsible Engineer/Team as a means to assure potential failure modes, causes and effects have beenaddressed for design related characteristics.

• Process An analytical technique used primarily by a Manufacturing.

Engineer/Team as a means to assure potential Failure modes.

causes and effects have been addressed for process related characteristics.

Our Focus is on Process FMEA

A structured approach to: Identifying the way in which a process can fail to meet critical

Customer requirements. Estimating the risk of specific causes with regard to these failures.

Evaluating the current control plan for preventing these failures from occurring.

Prioritising the actions that should be taken to improve the process.

STRUCTURE OF FMEA

Concept: To identify ways the product or process can fail and then plan

ComponentProving Process

Mistake ProofingTechniques

FMEA

ContinuousImprovement Programs

to prevent those failures, utilising mistake proofing tools and techniques.

Why we use FMEA rather than cure? Increase probability of DETECTION.

Identify biggest contributor to failures and eliminate them.

Reduce probability of failure occurring.

Build quality into the product & process.

When to use FMEA? FMEA is most beneficial as a “beforethe-event” action.

Design FMEA should be done during initial design of product.

Process FMEA should be done during design of manufacturing process.

.

P.P.A.P

Learning’s at Tata Motors

Being one of the most technically sound and having few of the costliest

technologies among the Asian automobiles, the culture in the Tata Motors is

free, motivating and appreciative.

Here the culture of Equality is fully nurtured all the people operator to senior

level are given equal respect through all the possible manner like same Canteen

facility, same transportation facility, same uniform among various levels.

The lesson of “Time is Money” & “Creativity is thinking up new things Innovation

is doing new things.” is taught from day 1 to all employees.

The lesson of “Appreciate your colleague’s work” is well taught from senior level

manager to all the man-force in TML, Pantnagar.

10) BIBLOGRAPHY

1. www.google.co.in

2. www.wikipedia.com

3. www.tatamotors.com

4. http://www.acmainfo.com/pdf/Status_Indian_Auto_Industry.pdf

(Graphs 2009, 15, 20).

5. http://www.imaginmor.com/automobileindustryindia.html (Pi charts)

6. http://www.tatamotors.com/know-us/milestone.php

7. http://www.tata.com/businesses/sectors/index.aspx?

sectid=aZ72PXPwpaI=#Informationsystemsandcommunications (Tata

Group of Companies)

8. http://www.exampleessays.com/viewpaper/17379.htm (1800 1st

automobile)