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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

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

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.

INDEX

S.NO

TOPIC

PAGE: NO

1.0

Introduction

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

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7.0

Advantages & Disadvantages

28

8.0

Safety precautions

29

9.0

Conclusion

30

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.
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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

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.

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 Protrusion Min. Corner Radius Min. Fillet Radius
mm
mm
mm
(in)
(in)
(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:

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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

2.2
Hand forging:

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

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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

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Tongs

Chisel

Fullering tool

Swage

3.0 Forging Operations:


Some of the forging operations are as follows:
1.
2.
3.
4.
5.
6.

Up setting
Roll forging
Piercing
Flattening
Drawing
Shaping
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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:

20

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.

S.NO

1.

FERROUS METAL

Low carbon steel

FORGING TEMP, IN
C

1250

2.

Medium carbon steel

850-1100

3.

Stainless steel

1200

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.
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S.NO

NON-FERROUS

FORGING TEMP

METALS

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


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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.

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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.

Height

625mm

Round

500mm

Temp. Range

0-600 C

Coil

Coil dia - 14mm


Wire dia - 2mm

Length of coil

4600mm

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].

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.
30

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.
31

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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