INTRODUCTION

Forging process may be defined as a metal working process by which metals or

alloys are plastically deformed to the desired shape by a compressive force applied with the
help of a pair of dies. One die is stationary and the other has a linear motion .Forging process
can be carried out both in cold and hot state of the metal. But, unless otherwise mentioned,
forging process is considered to be hot forging process.
Forging improves the quality of steel, which becomes stronger after forging. Due to
this, the parts which are subjected to heavy duty are generally made of forging. Time of
production is very often reduced. Much less steel is consumed in forging operation. Hence
the cost of any given part is reduced. In forge shops, steel is received as ingots or as rolled
sections. Ingots are used for manufacturing heavy forgings while rolled billets are used for
lighter forgings. Forgings, which have to undergo subsequent machining, are called blanks.
Those which do not need any further machining are called finished forgings.
Forgings may be produced in either open or close dies. In open die forging is also
known as flat die forging, the hot metal is struck or pressed between two flat surfaces or
simple contoured dies. The compressive force is progressively applied locally on different
parts of the metal shock. The flow of metal, that is, the changing of its dimensions and shape
is controlled with the aid of various blacksmiths tools.
In closed die forging process, cavities or impressions are cut in the die Block, the
compressive force is applied to the entire surface and the metal is forced to take its final
shape and dimensions as it flows into and fills the die cavities. The flow of metal is limited
by the surfaces of the recesses or cavities in the dies. When the pair of dies approaches each
other for completing the forging, the excess, metal squirts out of the cavity as a thin ribbon of
metal called flash. Because of flash, the term closed die forging is a bit of misnomer.
Closed die forging means no flash .so, a better description of the process with
recesses or cavities in the die blocks would be Impression die forging.

Open dies are less costly than impression dies and so are used where number of
components, to be forged is too small to justify the cost of impression dies, or where the
sizes are too large and too irregular to be contained in usual impression dies, Open die
forging can be used for simple shapes only such as :Bars ,slabs or billets with rectangular
,circular ,hexagonal ,or octagonal cross sections, welder rings, and many other components
of simple shapes. On the other hand, for more complex and accurate parts and with increased
production rates, impression dies are preferred.
In open die forging, the weight range of forging goes up to few tonnes, whereas in
impressions die forging, the weight range is limited

up to few hundred Newton due to

limitation of die size. In open die forging, the forgings are usually made on hydraulic presses
designed for forging ingots, where as impression die forgings are made on hammers or
presses(mechanical \hydraulic).Open die forgings are required for heavy equipment and
machinery such as for steel plants, power generation ,shipping and defense where as
impression die forgings are generally used in automobile sector. In open die forging, the
simplicity of tooling is gained at the expense of the complexity of process control, where as
in impression die forging, the process is simplified to a sequence of simple compression
strokes at the expense of complex die shape.
CHARATERISTICS OF CLOSED DIE FORGINGS
Closed die forgings have the following characteristics.
1. Saving of time as compared to open die forging.
2. Makes good utilization of work piece material.
3. Excellent productivity with good dimensional accuracy.
4. Forgings are made with similar machining allowances, thus reducing considerably the
machining time and the consumption of metal required for the forging.
5. Forgings of complicated shapes can be made.
6. The equipment for closed-die forging does not require highly skilled workers.
7. The grain flow of the metal can be controlled ensuring high mechanical properties.
8. Method is suited for rapid production rate

9. Cost of the tooling is high, therefore, suitable for large production areas.

CLASSIFICATION OF DIES
The dies used for closed-die forging or impression-die forging may be classified in to
two groups.
(i)SINGLE IMPRESSION DIE:
This die contains only one cavity or impression, which is the finishing impression.
The preliminary forging operations are done by hand or on forge hammers, forging rolls etc,
and only final finishing operation is done on the cavity.
(ii)MULTI IMPRESSION DIE:
This die contains finishing operation and one or more auxiliary impressions for
preliminary forging operations. The final shape of the part is progressively developed over a
series of steps from one die impression to the next. Generally multi-impression dies are very
expensive to make and are employed only when the quantity to be made is sufficient large,
and for forging of intricate designs.

ADVANTAGES OF MULTI-IMPRESSION DIE

1. Complete sequence of forging operations can be carried out on single equipment only,
avoiding the use of auxiliary equipment.
2. Use of multi-impression dies is suited for production of small and medium sized forgings
in large quantities as this method gives 2to3 times the production compared with the method
of production using a single die. This is because the time of production of the use on
auxiliary equipment is reduced or eliminated.
3. All the preliminary operations can be performed on these dies with good ease. The use
can be prepared to fairly accurate dimensions. Besides this more accurate forgings can be
prepared.
4. Wastage of forging metal is reduced

5. Use may not be reheated for the finishing impression.

6. Initial die cost becomes insignificant in case of high output.
7. Finishing impression lasts long, because, much of the load is taken by blocking impression.

THE IMPORTANCE OF THREE-DIMENSIONAL GEOMETRY

Early CAD systems were basically automated drafting systems, which displayed a
two-dimensional representation of the object being designed. Operators (e.g., the designer or
drafter) could use these graphics systems to develop the line drawing the way they wanted it
and then obtain a very high quality paper plot of the drawing. By using these systems, the
drafting process could be accomplished in less time, and the productivity of the designers
could be improved.
However, there was a fundamental shortcoming of these early systems. Although they
are able to reproduce high-quality engineering drawings effectively and quickly, these
systems stored in their data files a two-dimensional record of drawings. The drawings were
usually a three-dimensional objects and it was left to the human beings who read these
drawings to interpret the three-dimensional shape from the two-dimensional representation.
The early CAD systems were not capable of interpreting the three-dimensionality of the
object. It was left to the user of the system to make certain that the two dimensional
representation was correct as stored in the data files.
More recent computer - aided design systems posses the capability to define the
objects in three-dimensions. This is a powerful feature because it allows the designer to
develop a full three-dimensional model of an object in the computer rather than the two
dimensional illustration.
The computer can then generate the orthogonal views, perspective drawings, and
close-ups of details in the object. The importance of this three-dimensional capability in
interactive computer graphics should not be underestimated. It is important that the graphics
system work with three dimensional shapes in developing the model of the object.

FLANGE YOKE:
Flange yoke is a component used in propeller shaft of the automobiles. It is a component,
which is used for the transfer of power from the engine of the vehicle to the rear wheels. The
universal joint allows driving power to be carried through two shafts that are at an angle to
each other. The universal joint is a doubled hinged joint consisting of two flange yokes and a
cross-shaped member called the spider. One of the yokes is on the driving shaft and the other
on the driven shaft. The four arms of the spider called trunnions are assembled into bearings
in the end of the two shaft yokes. The driving shaft and yoke cause the spider to rotate. The
other two trunnions of the spider cause the driven shaft to rotate. When the two shafts are at
an angle to each other, the bearings in the flange yoke permit the yokes to swing around on
the trunnions with each revolution.

FORGING DIE DESIGN

Before designing the tools to produce a given forging, the shape of the final forging
has to be determined. There are certain underlying principles for achieving a practical and
economical forging design. The tool engineer must have a clear understanding of these
principles or factors, which are discussed below:
1. DRAFT:
It is the angle of taper put on all sides of the forging to facilitate its quick removal
from the die cavity after forging. In case of drop forging and press forging,

external
draft

internal
draft

the usual values of draft angle are: 3 to 7 for external surface &

5 to 10 for

internal surfaces.
If automatic ejection devices are employed to free the forging from the die cavity, the
draft angle can be reduced to 1. Draft is appreciably lowered in case of forging
machine since the stock is firmly held by gripping dies. It is some times as small as
1/2

2. FILLET AND CORNER RADII:

A fillet means the rounding of the apex of an internal angle and corner radius means
the rounding of the apex of the external angle. Sharp edges on the body of the forging
and hence the die cavity increases the tendency towards forging defects and
accelerates die wear. Also sharp edges will hinder the complete filling of the die
cavities. Therefore, generous fillet and corner radii are the most desirable features of a
closed - de forging because it assists the flow of hot metal and eliminates the
possibility of forging laps or shuts. Also, the premature die failures due to stress
cracks and abrasions are prevented. Hence, larger the fillet and corner radii, longer
will be the die life and better will be the forging quality. The usual values of fillet and
corner radii are given in table:

3. PARTING LINE:
The parting line is the line along the forging where the two halves of a pair of forging
dies meet. It divides the die impression into two parts from which one is made in the
top die and the other in the lower die. The shape and location of the parting line is
very Important as these have considerable influence on the flow of metal, die cost and
draft requirements, etc. regarding the location of the parting line, the die designer
should always remember the fundamental factor that in forging, the metals flows
much more easily in the lateral direction (path of least resistance) than in the direction
of applied force. Thus in forging process, it is easier to spread metal than to force it
into deep die impression. So in most forgings the parting line is at the largest cross
section of the part. Another fundamental factor is that the metal fills the top die first,
so the deep and intricate of the impression should be cut in the top die. When owing
to the shape of the forging, a complete impression is arrived at in on part of the die;
this should be the top die. In such a case the lower die remains without the impression
and will have only locating elements to secure the proper location of the forging.
Another factor in the selection of parting line is that should avoid deeper die
impressions to minimize die wear. Deeper die impressions would require high forging
pressure for complete filing and might lead to die breakage. A proper parting line may
eliminate the chances of grain flow reversal and improve the mechanical properties. A

parting line, which may not require any additional draft provided for easy removal of
forging from die, will result in large savings in machining cost and raw material.

4. SHRINKAGE AND DIE WEAR:

Before forging, the work material is heated to the forging temperature. During the
forging operation, it is in the process of cooling and consequently shrinking. To take
into account the expansion of the material at high forging temperature, the die cavities
are made corresponding larger by using a shrink scale. For steel, this allowance is
about16mm per meter.
Die to continuous use; the dimensions of the die do not remain the same. Die wear is
the difference in dimensions, which occurs due to abrasion of the die impression. This
is accounted for in the forging design as follows:
For forgings weighing up to about 45 N, the die wear allowance is taken as 0.4 to 0.8
mm for external as well as for internal surfaces. For forgings weighing from 90 to 225
N the allowance may increase from 1.6 mm to 2.4 mm.
5. MISMATCH:
In closed die forging it is very difficult to achieve perfect alignment of the two die
halves and either the upper or the lower die may shift during forging. This shift may
occur sideways or endways. The forging produced by shifted die will be mismatch.
The mismatch should be avoided amount of permissible mismatch is given in the
table.

6. FINISH ALLOWANCE:
Some forged parts require surface condition or accuracy, which may not be possible to
obtain during forging. For this, the parts will have to be subsequently machined. For
this purpose extra material is provided on the forging which may vary from 0.8 mm to
3.2 mm depending upon the material and relative size of the forging.

7. DIMENSIONAL TOLERANCES:
These are the variations permitted from the given or normal dimensions and these
may include thickness tolerances and length tolerance. Commercial tolerance for
thickness are as given below.

8. WEBS AND RIBS:

A web is usually the thinnest portion of a forging. It will cool first and when it goes
below the forging temperature, the forging pressure required increase rapidly. So,
webs less than about 4.74 mm thick are not usually practical. The ribs should be
proportionately low and wide. Their height should not be more than 8 times the width.
The minimum recommended rib thickness is equal to that for webs.

DIE MANUFACTURE
Below, discuss the various methods (conventional and latest) for cutting impression in the
die blocks.
MECHANICAL MACHINING PROCESS:
These are the most commonly used methods for manufacturing dies. The processes include:
turning, machining on planer, milling and grinding.
TURNING is used for cough and finish machining of rotary working surface, whereas for
rectangular and square die blocks, these operations are done on a PLANNER.
GRINDING is mainly used for finishing the surfaces.
The impressions are cut in the die block by highly skilled men who use the MILLING
MACHINE, specially designed for sinking dies.
Cutters of various types are used in accordance with the shape of each section of the
impression. But much of the accuracy of the die depends upon handwork performed after it is
sunk. The impressions are machined either by manual sinking after layout a/or by copy
milling using templates or patterns.
In copy milling, the following variations in the process are available. Manual copy milling,
where the feed of spindle is controlled by hand. Semi automatic copy milling, where the feed
in the longitudinal and lateral axes is automated but the vertical movement is controlled
manually. Automatic copy milling, where the movement of the cutting tool is controlled
automatically by the movement of a sensor over the surface of a 3D pattern. This method can
produce intricate surfaces economically on both small and large dies.
DIE SINKING STEP:

10

Holes are drilled in the sides of the die blocks opposite each other. Handling bars may be
inserted in these holes. This facilities case in lifting and handling heavy die blocks.
Next, the shanks for the attachment of the dies in the forging hammer or press are machined
on a planner.
1. Next, the die blocks are turned over the bed of the planer and the striking surfaces
are machined to obtain clean and sound metal for the impressions which are to be
sunk.
2. The die blocks are then squared which facilitate exact alignment of the die blocks
when placed in the forming hammer or press.
3. LAYING

OUT THE OUTLINE OF THE IMPRESSIONS :

Metal templates are made from

the blue print or model of the part to be forged. These templates are then used for
laying out the outline of the impressions, which are to be sunk in the die blocks. In
the absence of a template, the layout is made from the forging or die drawing. The
faces of the die blocks are given a color back ground by coating them with copper
sulphate or a similar purpose solution, to secure a convenient surface for the marking
of the outline of the impression.
4. MACHINE

WORK:

The first impression to be sunk is the finishing impression. If the

impressions are of simple shape, they are sunk on vertical milling machines, those of
intricate shapes are machined on die sinkers.
5. BENCH

WORK:

After sinking the impression, the hand work on the bench includes

operation such as scraping, filling, grinding and polishing the cavities. The finishing
impression must be true for every dimension. They must be lapped and polished free
of all tool marks and sharp corners, so that the impressions will allow the metal to
move with least resistance in filling the cavities of the dies.
6. PREPARATION

OF LEAD COST:

After the finishing impression has been completed,

the die blocks are clamped together in exact alignment. A lead antimony alloy is
poured in the finishing impression through a sprue, which is machined into each die
block from its outer edge and extends to the cavity of the finishing impression. The
resulting lead cast or proof is now carefully checked for dimensional accuracy by
the die maker, as well as by the engineer. The lead cast may also be checked by the
producer and the user of the forgings, before final approval for release for production
is obtained. Since steel shrinks on cooling from its forging temperature and the lead
alloy does not, it is necessary to allow for the shrinkage in checking the lead cast.

11

7. After lead cast has been approved, the sinking of the other impressions is begun. The
next impression to be sunk is the blocking impression. The rolling or edging
impression can next be sunk into the die block and so on.
8. The flash may begin to form at the blocking impression, but most of it will develop
at the finishing impression where the full impact of the hammer blows or full
pressure of press is utilized to the utmost. Thus, the blocking impressions are seldom
flashed or guttered, whereas the finishing impressions usually flashed in both sides,
and guttered, only in the top die. By flashing both dies, we get a neater and more
symmetrical appearance of the final forging. By guttering the top die only, the
forging will sit flush in the trimming die which must be used to trim the excess flash.
Machining of the flash gutter will complete the necessary machining work required
for a given set of forging dies.
Flash must be thin to aid die filling and produce close tolerances. It also acts as
safety valve for excess metal.
A thin flash running out between parallel die surfaces would lead to very large
length / thickness ratios and thus to high die pressures. Therefore, the length of flash
is reduced by cutting a flash gutter. This allows free flow of the flash and limits the
minimum flash thickness to only a small width. The width of the flash flash land is
given as,
Flash land = 3 to 5h, wide
9. Lastly, the die is given a final dressing to fillet all sharp corners at the flash line to
permit ease of metal flow.
10. Many dies are now surfaces treated for improved were resistance, by techniques
similar to those described for metal cutting tools.
Numerically Controlled Milling:
This technology is gaining importance due to the reduced time needed for making
dies. However, the application of this technology depends on the availability of a
numerical description of the die geometry and on the development of punched tapes.
For machining surfaces of relatively simple analytical description such as cylinders,
cones, spheres and second order surfaces, problem oriented programming languages

12

such as APT (automatic programmed tools) and EXAPT (extension of APT) have been
developed. These permit programming the cutter paths required to machine the entire
surface by means of a few appropriate instructions. The instructions are processed with
the help of processing programs (processor and post processor) using a suitable
computer. Complex surfaces may be described by using suitable mathematical surface
models generated directly by CAD or indirectly by digitizing from technical drawings or
from measurements made on 3D models.
Limitations of copy milling and NC milling:
In addition of the limitation set by the relationship between the shape to be machined
and the cutting tool as well as by the tolerance requirements, another limit is set by the
fact that the shaft diameter and the tip radius of the sensor (stylus) following the pattern
cannot be infinitely small because of probing forces involved. Therefore, die cavities
with sharp small corner radii can not be machined easily by milling. The critical limit is
given by the loading of the cutting tool. It is reached when materials with strength of
greater than 1300 MPa are machined. The machining of dies in the annealed state, where
the material strength is 700 to 800 MPa, raises the performance of these milling methods
considerably and should be preferred.
E.D.M: Electro Discharge Machining (EDM) is an electro-thermal non-traditional
machining process, where electrical energy is used to generate electrical spark and
material removal mainly occurs due to thermal energy of the spark.
EDM is mainly used to machine difficult-to-machine materials and high strength
temperature resistant alloys. EDM can be used to machine difficult geometries in small
batches or even on job-shop basis. Work material to be machined by EDM has to be
electrically conductive. In EDM, a potential difference is applied between the tool and
work piece. Both the tool and the work material are to be conductors of electricity. The
tool and the work material are immersed in a dielectric medium. Generally kerosene or
deionised water is used as the dielectric medium. A gap is maintained between the tool
and the work piece. Depending upon the applied potential difference and the gap
between the tool and work piece, an electric field would be established. Generally the
tool is connected to the negative terminal of the generator and the work piece is
connected to positive terminal. As the electric field is established between the tool and
the job, the free electrons on the tool are subjected to electrostatic forces. If the work

13

function or the bonding energy of the electrons is less, electrons would be emitted from
the tool (assuming it to be connected to the negative terminal). Such emission of
electrons are called or termed as cold emission. The cold emitted electrons are then
accelerated towards the job through the dielectric medium. As they gain velocity and
energy, and start moving towards the job, there would be collisions between the
electrons and dielectric molecules. Such collision may result in ionisation of the
dielectric molecule depending upon the work function or ionisation energy of the
dielectric molecule and the energy of the electron. Thus, as the electrons get accelerated,
more positive ions and electrons would get generated due to collisions. This cyclic
process would increase the concentration of electrons and ions in the dielectric medium
between the tool and the job at the spark gap.
The concentration would be so high that the matter existing in that channel could be
characterised as plasma. The electrical resistance of such plasma channel would be
very less. Thus all of a sudden, a large number of electrons will flow from the tool to the
job and ions from the job to the tool. This is called avalanche motion of electrons. Such
movement of electrons and ions can be visually seen as a spark. Thus the electrical
energy is dissipated as the thermal energy of the spark.
The high speed electrons then impinge on the job and ions on the tool. The kinetic
energy of the electrons and ions on impact with the surface of the job and tool
respectively would be converted into thermal energy or heat flux. Such intense localised
heat flux leads to extreme instantaneous confined rise in temperature which would be in
excess of 10,000oC.
Such localised extreme rise in temperature leads to material removal. Material removal
occurs due to instant vaporisation of the material as well as due to melting. The molten
metal is not removed completely but only partially.
As the potential difference is withdrawn as the plasma channel is no longer sustained. As
the plasma channel collapse, it generates pressure or shock waves, which evacuates the
molten material forming a crater of removed material around the site of the spark.
Thus to summarise, the material removal in EDM mainly occurs due to formation of
shock waves as the plasma channel collapse owing to discontinuation of applied
potential difference.
Generally the work piece is made positive and the tool negative. Hence, the electrons
strike the job leading to crater formation due to high temperature and melting and
material removal. Similarly, the positive ions impinge on the tool leading to tool wear.
14

DIE - DESIGN OF AN FLANGE YOKE

As already noted the dies are made in sets of halves. One - half the die is attached to the ram
and the other stationary anvil. The die halves may be having one or more than one
impressions. In single impression dies, die impression is the finishing impression; the
preliminary forging operations are done on other machines such as forging roles, up setter
and benders etc. Multi impression dies may have two (blocking and finishing) or more than
two impressions. In these dies the final shape of the forging is progressively developed over a
series of steps from one die impression to the next. Each impression gradually distributes the
flow of metal and changes the shape of work - piece as it is transferred from one impression
to next between strokes.
The art of forging die design aims at determining the minimum number of steps the lead from
the starting material (usually a round or rectangular bar) to the finishes shape.
For a multi-impression die the preliminary forging operations or the perform operations that
are usually required in shaping the part is generally classified as:
1. Fullering or swaging
2. Edging or rolling
3. Bending
4. Drawing down or drawing out or cogging
5. Flattening
6. Blocking
The other operations on such a die are:
7. Finishing operation
8. Cut off

15

The forging operations that are required in shaping the FLANGEYOKE are
1. BUSTER
2. BLOCKING
3. FINISHING OPERATION

1. BUSTER:
This is usually the first operation performed on the heated rectangular bar. The basic
function of this operation is that it moves the various parts of the stock in to a proper relation
with shape of the finishing impression where such a section is of non-symmetrical in section.
In these die the bottom die half is flat and the top die half contains the ribs shape of the flange
yoke. The gap between the top die half and the bottom die half is maintained as 20mm.A draft
angle of 5 degrees is maintained at the corners of the top die so that the component is easily
removed from the die cavity .To the inner edges, fillet of radius 15mm is given.
One blow is generally required for this operation.
2. BLOCKING:
Blocking impression or the blocker also called, as semi-finishing impression is the
streamlined model of the finishing impression and required on some types of forging for one
or both the general reasons. The first and the more important reason is that the finishing
impression may contain too many obstructions in the form of depressions, holes, bosses,
plugs or abrupt contours or section changes, to permit a normal flow of metal to all parts of
the impression without further preparations from the preceding operations. The blocking
impression has the general shape of the finishing impression. The blocking impression has
the general shape of the finishing impression but with all the corners, holes and abrupt section
changes thoroughly rounded so that plastic metal may be moved into suitable position for

16

more exact c=shaping the finishing operation. Blocking impression aids in prevention of the
forging defects such as cold shuts.

Second reasons for the use of blocking impression are to reduce the wear of the finishing
impression. Excessive wear of the finishing impression reduces the useful die life. In case of
certain forgings, which are symmetrical in shape, the blocking impression is only a
preparatory impression. In blocking impression, the length and width smaller, the height or
thickness is more, but the center distance is the same as in the final impression. The
difference may be 1to 2 mm on each side, but higher clearance of 3 to 5mm can be
recommended where partial displacement of metal occurs. For flange yoke the difference is
taken as 5mm.
One blow is generally required for blocking operations.
3. Finishing Impression:
This impression represents the exact shape of the finished forging. The shape and size
of the finishing impression is checked in the process of manufacture of die by plaster of Paris
or lead cast. The finishing impression is located in the middle of the die block but it is not
necessarily in its central axis. However, it is vital to locate the final impression in such a
manner that there will be no horizontal forces that give a side thrust and make as die shaft. It
is this advisable to have the loud center of forging directly below the axis of ram.
Flash cutter
The flow of plastic metal under the blows of the drop banner or the pressure of
forging press, proceeds first to fill up the finishing impression and then a small quantity of
the extra metal moves into shallow cavity provided a round the finishing impression of the
die. These small cavities which are directly outside the die impression are known as flash
gutter. The flash gutter is separated from the die impression by narrow passage, which is the
flash land. The volume of the flash land and the flash gutter should be about 20% to 25% of
the volume forging.
The amount of excess metal from the finishing impression may be too large to permit
the complete closing of the dies. The gutter is provided to ensure complete closing of the die.
It acts as storage for the excess material after it is passed through the flash land. Too large a
17

gutter reduces the striking area for the die surfaces. Alternatively, too small a gutter will
result in extrusion of flash between the striking surfaces of the die, resulting in an oversize
forging
The dimensions of the gutter may be taken from the table given below:

Stock size, mm

Gutter Thickness

Dimensions, mm.
Width

Upto 38

3.2

25.4

38 to 50

4.8

25.4 to 31.75

50 to 63.5

4.8

31.75 to 38

76 to 100

6.4

38 to 44.5

CUT OFF
When the forging are made from the bar stock, they are must be cut off after the
forging operation is completed. This is done either by special side cutter of the trimming
press or by the cut if impression milled usually in the left back corner of the die block or by a
trimming designed for the purpose.

18

HOT FORGING PROCESS OF FLANGE YOKE

5.1 RAW MATERIAL INSPECTION:

The material is inspected by general tests like:
1. Visual inspection
2. Spark testing
3. Spectral testing
4. Chemical analysis
5. Hardness testing
6. Macro examinations
7. Micro examinations
8. Grain size
9. Inclusion rating
10. Upsetting testing
11. Gas content analysis

19

The raw material used in manufacturing of automobile flange yoke is 37c15.It

generally contains 0.37% carbon and 1.5% manganese and other chemical properties,
raw material is shown in the above fig.
Whether raw material is within limits (as mentioned by customer) they usually
prefer for better inspection as here they used spectral analysis.
The spectral analysis consists of a spectrum machine which is capable of
showing around 16 elements present in the raw material.
It is usually tested by the concept of emission of wave and calculating the
content of elements.
The gas used in this spectrum machine is inert gas.

20

The machine used here is METAVISION 108

21

5.2 CUTTING SECTION:

The raw material which is in round or rectangular bars with a huge length is passed
into this cutting section as to cut in required lengths. Usually to cut that bars we use band saw
machine or shearing machine and nowadays CNC machines.
5.3 FORGING SECTION:
The raw material is passed into the furnace as the hot forging indicates working above
the recrystalisation temperature but below boiling point. Usually the furnaces used are oil
type, induction type. The hot bar is placed in press forging or drop hammer containing top
die and bottom die. When the ram blows the bar then the metal takes shape of a die.
Depending upon the component the die contains buster, blocker, and finisher.

5.4 INSPECTION:
THE VERNIER CALLIPER
The principle of vernier is that when two scales or divisions slightly different in size
are used, the difference between they can be utilised to enhance the accuracy if measurement.
The vernier caliper essentially consists of two steel rules and these can slide along each other.
One of the scales, i.e., main scale is engraved on a solid L-shaped frame .On these scale cm
graduations are divided into 20 parts so that one small division equals 0.05 cm. One end of
the frame contains a fixed jaw which is shaped into a contact tip at its extremity.
VERNIER HEIGHT GAUGE
Most Suitable for tool room and quality control applications. Manufacturing areas
with fine adjustment.

22

 Stainless Steel Holding Brackets.

Least Count 0.02 mm.

Scale made from Stainless Steel.
Removable Carbide Tipped Point.
Reading Faces are Dull Chrome.

DEPTH GAUGE
6" Steel Rule with Hardened and Ground Steel Base.

Spring tension Nut for easy depth measurement.

Graduated in inches and mm.

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SURFACE MARKING BLOCK / GAUGES (Round Base)

Sturdy construction surface gage.

Consists of Adjusting knob and hardened scriber.

Round base made of close grain Cast Iron.
Very useful for every workshop.

FINAL INSPECTION:
GAUGES are inspection tools of rigid design, without a scale, which serve to check
the dimensions of manufactured parts. Gauges do not indicate the actual value of the
inspected dimension on the work. They can only be used for determining as to whether the
inspected parts are made within the specified limits. Gauges usually used for checking are
plug gauges for checking holes, snap and ring gauges for checking shafts.

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5.5 HEAT TREATMENT

TYPES OF HEAT TREATMENT:
Four basic types of heat treatment are used today. They are normalizing, hardening,
and tempering. The techniques used in each process and how they relate to Steelworkers are
given in the following

NORMALIZING:
Normalizing is a type of heat treatment applicable to ferrous metals only. It differs
from annealing in that the metal is heated to a higher temperature and then removed from the
furnace for air cooling. The purpose of normalizing is to remove the internal stresses induced
by heat treating, welding, casting, forging, forming, or machining. It is frequently applied as
the final heat treatment process on items which are subjected to relatively high stresses.
Usually, low-carbon steels do not require Normalizing; however, if these steels are
normalized, no harmful effects result. It usually heated at temperature of 86040c and held
there for a specified period.

HARDENING:
The hardening treatment for most steels consists of heating the steel to a set
temperature and then cooling it rapidly by plunging it into oil, water, or brine. Most steels
require rapid cooling (quenching) for hardening but a few can be air-cooled with the same
results. Hardening increases the hardness and strength of the steel, but makes it less ductile.
Generally, the harder the steel, the more brittle it becomes. To remove some of the brittleness,
you should temper the steel after hardening. Many nonferrous metals can be hardened and
their strength increased by controlled heating and rapid cooling. In this case, the process is
called heat treatment, rather than hardening. To harden steel, you cool the metal rapidly after
thoroughly soaking it at a temperature slightly above its upper critical point. The addition of
alloys to steel decreases the cooling rate required to produce hardness. A decrease in the
cooling rate is an advantage, since it lessens the danger of cracking and warping.

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Pure iron, wrought iron, and extremely low-carbon steels have very little hardening
properties and are difficult to harden by heat treatment. Cast iron has limited capabilities for
hardening. When you cool cast iron rapidly, it forms white iron, which is hard and brittle.
And when you cool it slowly, it forms gray iron, which Is soft but brittle under impact.

TEMPERING:
After the hardening treatment is applied, steel is often harder than needed and is too
brittle for most practical uses. Also, severe internal stresses are set up during the rapid
cooling from the hardening temperature. To relieve the internal stresses and reduce
brittleness, you should temper the steel after it is hardened. Tempering consists of heating the
steel to a specific temperature (below its hardening temperature), holding it at that
temperature for the required length of time, and then cooling it, usually instill air. The
resultant strength, hardness, and ductility depend on the temperature to which the steel is
heated during the tempering process. The purpose of tempering is to reduce the brittleness
imparted by hardening and to produce definite physical Properties within the steel. Tempering
always follows, never precedes, the hardening operation. Besides reducing brittleness,
tempering softens the steel. That is unavoidable, and the amount of hardness that is lost
depends on the temperature that the steel is heated to during the tempering process. That is
true of all steels except high-speed steel.

QUENCHING MEDIA:
The cooling rate of an object depends on many things. The size, composition, and
initial temperature of the part and final properties are the deciding factors in selecting the
quenching medium. A quenching medium must cool the metal at a rate rapid enough to
produce the desired results. Mass affects quenching in that as the mass increases, the time
required for complete cooling also increases. Even though parts are the same size, those
containing holes or recesses cool more rapidly than solid objects. The composition of the
metal determines the maximum cooling rate possible without the danger of cracking or
warping. This critical cooling rate, in turn, influences the choice of the quenching medium.
The cooling rate of any quenching medium varies with its temperature; therefore, to get
uniform results, you must keep the temperature within prescribed limits.
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HARDNESS is a property of material which is defined as the resistance to penetration,

abrasion, scratch cutting etc. The hardness is usually calculated by Brinell hardness test after
hardening, normalizing, tempering.
BRINELL

HARDNESS TEST :

This determines the resistance of a material to penetration.

Hardness is determined by measuring the impression made by steel ball forced into specimen
under a predetermined load. It has got only one scale of hardness and Brinell hardness
number is defined as the average axial stress over the surface of the indentation produced by
the steel ball, assuming the indented surface is spherical. The advantage of Brinell hardness
test is that it has got direct relations with maximum tensile strength of the material. The
diameter of the spherical impression is measured by a high magnification microscope and the
spherical area calculated from the diameter of impression and diameter of ball. The surface to
be tested must be smooth and free from surface defects.

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CONCLUSION
The die design plays vital role in designing a component. The solid models of automobile
components like flange yoke have been created with help of an AUTOCAD and other modern
softwares. These are the similar process involved in manufacturing of any automobile
component. Hot forging process is generally employed for main automobile components.
Depending up on component size and shape the forging section is done. The initial inspection
is main method to check the errors. After forging process the component is sent here to check
all the primary errors like change in length and height, width and other errors. If we found
any error the component is not further processed, if there is no error it is sent to next section
that is heat treatment. After heat treatment it is sent to the crack detection method to found
cracks in the component. Cold coining process, it is very important section. It is used to
eliminate bending in the component, it makes component straight. And at last final inspection
is done. And finally to dispatch.

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REFERENCE

1.

PRODUCTION TECHNOLOGY

BY R. K. JAIN

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