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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)
(Sr. professor)
(External guide)
(Internal guide)
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
CERTIFICATE
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.
(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.
Forging
2)
Cut to lengths.
INDEX
S.NO
TOPIC
PAGE: NO
1.0
Introduction
2.0
11
Forging operations
18
3.1 Up-setting
3.2 Roll-forging
4.0
20
5.0
22
27
7.0
28
8.0
Safety precautions
29
9.0
Conclusion
30
10.0
Bibliography
31
HISTORY:
1.0 INTRODUCTION:
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.
10
Material
Draft Angle ()
Aluminum
0-2
0-3
Steel
5-7
Stainless Steel
5-8
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.
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.
13
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.
14
15
Twist hammer
Bush hammer
Sledge hammer
Dog-head hammer
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.
17
Tongs
Chisel
Fullering tool
Swage
Up setting
Roll forging
Piercing
Flattening
Drawing
Shaping
18
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.
Ferrous metals:
20
S.NO
1.
FERROUS METAL
FORGING TEMP, IN
C
1250
2.
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
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.
21
S.NO
NON-FERROUS
FORGING TEMP
METALS
IN C
1.
Brass
650-800
2.
Bronze
825-900
3.
Aluminum alloys
350-450
22
Continuous furnaces
Oil furnace
Pit furnace
Specifications:
Features:
24
Specifications:
25
ground level.
Height
625mm
Round
500mm
Temp. Range
0-600 C
Coil
Length of coil
4600mm
27
Up-setting
Punching
Roll forging
Flattening
Manufacturing Process:
Forging Process Flow Chart:
28
29
Advantages:
9 More uniform structure with directional characteristics.
9 Minimum cavities and blow holes.
9 High mechanical strength and toughness.
30
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.
9 To observe strictly all labour safety laws and all safety engineering
rules and regulations during work.
9.0 CONCLUSION:
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.
32
33
34
35
36