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CHAPTER-1
COMPANY PROFILE
VFIL is established in the year of 1963. It is introduced as a well-versed
organization under taking all types of precision components. They are here with giving
Machinery available with them. VFIL can undertake your components for Machining
& Grinding Operations. Also, they are taking Forgings and Heat Treatment Operations.
Since the undersigned has having Fifteen Years Technical Experience & Well Versed
with ISO Quality system. We can ensure you good quality, keeping in time delivery
with competitive marketing prices. We request you to off-load of your requirement,
which will have prompt attention.
A Company trusted by Customers for its consistently right quality forged products
for the last 35 years.
A Company that believes that it is not just the size that matters but quality and
consistency count and speak more of the Company.
A Company that believes in sound metallurgy in whatever it produces.
A Company whose top management has a commitment for Quality and Delivery.
A closely held Public Limited Company headed by a well-meaning Board of Directors
and Steered by a well-qualified Managing Director, a Mechanical Cum Metallurgical
Engineer with long years of experience.
With captive machine and heat treatment shops and in-house testing facility VFIL is an
integrated medium sized forge Company that can satisfy the requirements of the most
demanding customers.
A Company serving the best of names in the Public and Private sectors engaged in the
power and earth – moving sectors and other infrastructural segments of the Indian
Industry.

1.1 COMPANY REVIEW

A Compliment of about 100 + employees including managerial Staff and
Workmen keep the wheels of activity moving.
A broad split-up consists of :
 Ten Senior Executives (Two for quality).
 Fifteen supporting executives (Five for quality).
 Thirty-five highly skilled workers (Three for quality).

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 Twenty semi-skilled workers.

 Twenty-Five un-skilled workers.
The Company has a hierarchical structure with well-defined lines of authority,
accountability and responsibility. And the team is headed by a well-qualified and
academically acclaimed professional Managing Director with long years of
experience.

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CHAPTER-2
INTRODUCTION
VFIL is a consistently profit making and dividend paying Company, with
adequate working capital resources. The Company is highly rated by State Bank of
Mysore who provides working capital. The Company is also well rated by CRISIL
indicating high performance capability with financial strength.

VFIL is consisting of following departments is as follows: -

 Raw material department
 Planning department
 Production department
 Quality assurance and controlling department
 Marketing department

Raw material department: - The importance of raw material to efficient operation

of a manufacturing organization cannot be over emphasized; in that the availability
of the raw material in the right quality, quantity will determine the reasonable extent;
the availability, quality and quantity of the resultant output.

Figure (2.1) Raw material department flow chart

Planning department: - planning can become a management process, concerned

with defining goals for a future direction and determining on the missions and

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resources to achieve those targets. To meet the goals, managers may develop plans
such as a business plan or a marketing plan.

Figure (2.2) Planning department flow chart

Production department: - A production department is a group of functions within a

business that is responsible for the manufacture of goods. The production department
can be the largest organization within a business. It may employee mechanics,
machine setup specialists, maintenance personnel, and machine operators.

Figure (2.3) Production department flow chart

Quality assurance and controlling department: - Quality control (QC) is a
procedure or set of procedures intended to ensure that a manufactured product or
performed service adheres to a defined set of quality criteria or meets the
requirements of the client or customer. QC is similar to, but not identical with,
quality assurance (QA).

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Figure (2.4) Quality assurance and controlling department flow chart

Marketing department: - A marketing department promotes your business and

drives sales of its products or services. It provides the necessary research to identify
your target customers and other audiences. Depending on the company's hierarchical
organization, a marketing director, manager or vice president of marketing might be
at the helm.

Figure (2.5) Marketing department flow chart

2.1 QUALITY SURVEILLANCE

 Procurement of arc-furnace grade fully killed steels.
 Ensuring right chemistry, fine grained steel with the least of inclusions
 Checking for internal soundness of steels.
 Forging ensures adequate reduction ratio (1:3 minimum).
 Heat-treatment at suitably defined temperatures & with right soaking times.

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 Traceability heat-wise & heat-treatment batch-wise.

 Proving mechanical properties for each heat-treatment batch.

2.2 A few Quality norms adopted in VFIL

 Unless otherwise specified by the customer VFIL, as a standard keeps up to
the following metallurgical norms among several others, as illustrated.

2.3 Ultrasonic testing acceptance norms

100% of steels on receipt and 100% of all finished goods are tested for ultrasonic
soundness as per ASTM A 388 Standards.
The following are considered
“Unacceptable defects” (max. permissible) unless otherwise specified by the
customer;
 Cracks, flakes, seams & laps.
 Defects giving indication larger than that from a 4 mm diameter equivalent flaw.
 Groups of defects with maximum indication less than that from a 4 mm diameter
equivalent flaw which cannot be separated at testing sensitivity if the back echo
is reduced to less than 50%.
 Defects giving indications of 2 to 4 mm diameter equivalent flaw separated by
a distance less than four times the size of the larger of the adjacent flaws.

2.4 Micro Analysis norms

 For carbon and direct hardening alloy steels, ferritic grain size of 5 min. on
ASTM-E112 scale.
 For low-carbon and carburizing grade alloy steels, grain size is ASTM 5 or
finer but tested on austenetised sample.
 Jominy hardenablity determined by End-Quench test (IS-3848) and typical
values certified by VFIL (Unless otherwise specified by customer)
 For direct hardening alloy steels (like EN19, EN24 or equivalent)




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2.4.1 (HRC values at distances 1/16th inch from quenched end)

1 3 5 7 9 11
Max 60 60 59 58 57 55
Min 53 52 51 48 44 39

2.4.2 Like-wise case hardening grade alloy steels (like EN354, SAE
8620 or such equivalent)
1 3 5 7 9 11
Max 48 44 37 32 29 27
Min 41 32 23 - - -

Normalized structure ensures uniformly distributed ferrite-pearlite with no low

temperature transformation products.

2.5 VFIL is proud to have prestigious approvals:

 Accredited as a “Well-Known Forge” under Indian Boilers Regulations.
 RDSO approved for supply of safety items for Indian Railways. (Traction Motor
Shafts).
 Approved by NTPC for supply of critical components to high pressure & high
temperature boilers and accessories.
 Approved by ISRO for supply of components to space sector.
 Approved for defense supplies.

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CHAPTER-3
TASKS PERFORMED
Vishnu forge industries are well-versed and well qualified industry. It is
committed on timely deliveries of the appropriate priced products of the requisite
quality through well -defined process controls ensuring traceability with flexibility
in operations to manage any changes in business environment through continual
improvement of the quality management system.
3.1 Vishnu forge industry performs following tasks is as follows: -
 Forging
 Heat treatment
 Grinding
 Machining
Forging: - Forging is the process of manufacturing process involving the shaping of
metal using localized compressive forces. The blows are delivered with hammers or
a die. Forging is often classified according to the temperature at which it is
performed.

Figure (3.1) Forging

Heat treatment: - Process in which a metal is heated to a certain temperature and
the cooled in a particular manner to alter its internal structure for obtaining desired
degree of physical and mechanical properties such as brittleness, hardness, and
softness.

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Figure (3.2) Heat treatment furnace

Soaking: - Once a metal part has been heated to the temperature at which desired
changes in its structure will take place, it must remain at that temperature until the
entire part has been evenly heated throughout. This is known as soaking. The more
mass the part has, the longer it must be soaked.

Cooling: - After the part has been properly soaked, the third step is to cool it. Here
again, the structure may change from one chemical composition to another, it may
stay the same, or it may revert to its original form. For example, a metal that is a solid
solution after heating may stay the same during cooling, change to a mechanical
mixture, or change to a combination of the two, depending on the type of metal and
the rate of cooling. All of these changes are predictable. For that reason, many metals
can be made to conform to specific structures in order to increase their hardness,
toughness, ductility, tensile strength, and so forth.
3.2 Types of heat treatment: -
 Annealing
 Normalizing
 Quenching or Hardening
 Tempering
 Austempering
 Ausforming

Annealing:- Annealing is the process of heating a metal or alloy to a temperature

below its melting point in order to make it softer. Metals are annealed to relieve

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internal stresses, soften them, make them more ductile, and refine their grain
structures. Metal is annealed by heating it to a prescribed temperature, holding it at
that temperature for the required time, and then cooling it back to room temperature.
The rate at which metal is cooled from the annealing temperature varies greatly. Steel
must be cooled very slowly to produce maximum softness, This can be done by
burying the hot part in sand, ashes, or some other substance that does not conduct heat
readily (packing), or by shutting off the furnace and allowing the furnace and part to
cool together (furnace cooling).

Figure (3.3) Annealing graph

Normalizing: - Ferrous metals are normalized to relieve the internal stresses produced
by machining, forging, or welding. Normalized steels are harder and stronger than
annealed steels. Steel is much tougher in the normalized condition than in any other
condition. Parts that will be subjected to impact and parts that require maximum
toughness and resistance to external stresses are usually normalized. Normalizing
prior to hardening is beneficial in obtaining the desired hardness, provided the
hardening operation is performed correctly. Low carbon steels do not usually require
normalizing, but no harmful effects result if these steels are normalized. Normalizing
is achieved by heating the metal to a specified temperature (which is higher than either
the hardening or annealing temperatures), soaking the metal until it is uniformly
heated, and cooling it in still air.

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Figure (3.4) Normalizing graph

Hardening: - A ferrous metal is normally hardened by heating the metal to the required
temperature and then cooling it rapidly by plunging the hot metal into a quenching
medium, such as oil, water, or brine. Most steels must be cooled rapidly to harden
them. The hardening process increases the hardness and strength of metal, but also
increases its brittleness.

Tempering: - Steel is usually harder than necessary and too brittle for practical use
after being hardened. Severe internal stresses are set up during the rapid cooling of the
metal. Steel is tempered after being hardened to relieve the internal stresses and reduce
its brittleness. Tempering consists of heating the metal to a specified temperature and
then permitting the metal to cool. The rate of cooling usually has no effect on the metal
structure during tempering. Therefore, the metal is usually permitted to cool in still air.
Temperatures used for tempering are normally much lower than the hardening
temperatures. The higher the tempering temperature used, the softer the metal
becomes. High-speed steel is one of the few metals that become harder instead of softer
after it is tempered.

Figure (3.5) Tempering graph

Ausforming:- Ausforming also known as Low and High temperature thermo
mechanical treatments is a method used to increase the hardness and toughness of an
alloy by simultaneously tempering, rapid cooling, deforming and quenching to change

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its shape and refine the microstructure. This treatment is an important part in the
processing of steel.

Grinding:- Grinding is an abrasive machining process that uses a grinding wheel or

grinder as the cutting tool. Grinding is a subset of cutting, as grinding is a true metal-
cutting process.

Machining:- Machining is the process of cutting, shaping, or removing material from

a work piece using a machine tool.

3.3 Products produced at Vishnu forge industry:-

 Flanges
 Hubs
 Shafts
 Nodes & Cones
 Disks
 Rotor shafts
 Die forgings
 Sprocket shafts
 Washing machine flanges

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CHAPTER -4
SEAMLESS ROLLED RING FORGING PROCESS

Ring Rolling is a particular rolling process characterized by a decreasing time-

depended rolls gap. Two different couples of rolls move toward each other in order to
deform the width and the height of a starting hollow preform. The decreasing width and
height dimensions results in a diameter expansion so that a seamless and axis
symmetrical ring is produced. In figure 1 a scheme of the process is summarized: a
hollow circular preform is placed over an Idle roll that forces the ring against a Driver
roll. At the same time, the Axial rolls apply pressure in a direction parallel to the ring
axis. Because the ring does not rotate on its own axis, two Guide rolls are designed to
help the stability of the process. The coupled Idle and Axial rolls displacements define
the shape of the cross section and the increase of the ring diameter.

Fig (4.1) Main scheme of the process

As it can be observed in figure11 two independent deformation processes

simultaneously occur: one defined by the Idle roll displacement vs the Driver roll and
the other defined by the Axial rolls movement. Because each roll’s displacement could
be set independently from the other rolls in the industrial environment a milling curve
is introduced. The aim of this curve is to monitor the shape of the ring during the
deformation in order to ensure a correct ring production: in this curve the instantaneous
ring height (H) is plotted as a function of the instantaneous ring width (W) (Fig.12.a).

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Fig (4.2a): Milling curve for a Ring Rolling process. Fig (4.2b): Fishtail defect

This curve is fundamental because an incorrect milling curve could generate

undesired Ring Rolling defects as a too excessive fishtail (Fig. 12.b). Moreover
realizing the milling curve in a too short time means to have a situation in which the
fishtail defect becomes unrecoverable. On the opposite, a too long time means a too
high temperature decrease.
In literature many Authors focused their attention on the optimization of several
and different Ring Rolling parameters: Lin et Zhi
1. Developed a mathematical model to evaluate, as a function of the Driver and
Idle roll diameters, the extremum Idle roll feed speed needed to ensure a rotating
and an expanding ring. Starting from these results Yan et al.
2. Propose some relationships to correlate the Idle speed to the ring outer diameter
grown rate in case of cold Ring Rolling process. Anjami et Basti
3. By means of FE approach, focused their research to find optimum dimensions
of Driver and Idle rolls under which the strain and temperature distributions
within the ring are the most uniform and the fishtail defect has reasonable
values. Wang et al.
4. Proposed a computer program based on the optimization of objective functions
whose target is to control the motion of the Guide and Axial rolls for saving the
rolling time. The effects of the Axial rolls motions on the Ring Rolling process
was investigated by Hua et al.
5. And a mathematical model was presented to individuate a range of motion
parameters to ensure good stability of the process. Moreover Guo et Yang
6. Developed a set of mathematic correlations for the rolls speed to individuate
steady forming condition for the process based on a constant growth velocity

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condition of the ring. It is important to underline that all the mathematical

models available are based on a constant speed imposed to each rolls; this
assumption in industrial environment is not always followed and usually an
experimental laws for each roll is set based on the experience of the operator.
In this work a Ring Rolling case study was modeled by a numerical approach: different
milling curves characterized by different Idle and Axial roll speeds laws (constant,
linear and quadratic) were designed and simulated in order to increase the knowledge
about their influence on the ring production. The results were discussed in order to
identify the best set of Idle and Axial roll speed laws that guarantee a good quality
produced ring (lower fishtail) with lower loads and energy needed to manufacture it.

4.1 Modelling Set Up

In the present paper the new Deform 3D subroutine: Ring Rolling module,
based on Arbitrary Lagrangian–Eulerian (ALE) approach [7], was used to simulate the
Ring Rolling process. This FEM engine is extremely efficient and it was specifically
designed for Ring Rolling studies. Due to this new subroutine a decrease of the
computational time is observed (days instead of weeks). The model uses hybrid mesh
elements, which include hexahedra elements to map the edge of the ring and tetrahedral
element for the cross section; a rigid-plastic model is adopted to improve the
computational accuracy. Moreover, a different element concentration to reduce the
computational time is adopted too: as can be observed in Figure 3 a coarse mesh is
adopted to model the ring but an high elements concentration is designed in the gap
between the Idle and Driver roll and between the Axial rolls. The remeshing strategy
was also selected to reduce element distortion and to maintain a high quality mesh
during the simulation. Another important aspect is related with the stability of the
process: as it can be observed in Figure 1 an asymmetric deformation is induced on the
workpiece, this phenomenon generates a continuous shifting of the rotational axis.
Usually in industrial environments a pair of Guide rolls is used to keep the ring central
and maintain circularity. The software, due to self centring properties, lets to simulate
the process without the Guide rolls. Moreover, due to the nature of the process, it is
possible to reduce the number of elements, and so the computational time, by
considering a symmetric model. In Figure 3 the main objects involved the ring rolling
simulation are summarized.

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For determining the reliability level of the model developed in the numerical
approach a preliminary comparison with experimental values was needful. In a former
work the Authors tested the model reliability by comparing simulated and experimental
results, the accuracy of the FE model was analyzed based on a dual comparison of
geometrical and physical aspects and a good agreement (geometrical error less than
5%, loads error less than 15%) was found between experimental and numerical results.

Fig (4.3) 3D-FE scheme of the ring rolling process model

Based on these considerations two different numerical campaigns were

designed in order to study the influence of the Idle and Axial speed law on the ring
production. The simulations were set as isothermal and the working temperature of all
the processes was set equal to 1150 °C; the isothermal setting is reasonable because the
cooling could be considered as negligible due to the bulk dimensions of the workpiece
(the starting bar weight is about 3.5 ton) and to the short time needed to deform it (160
s). All the tools were simulated as rigid bodies and between the rolls and the workpiece
a shear friction factor equal to 0.7 was set. This value is suggested by the software in
case of hot forging process. The first campaign was focused on the Idle roll influence
while the second one on the Axial rolls. In Table 1 and Table 2 the main dimensions of
the ring and rolls are respectively reported.

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4.2 First numerical campaign

In order to study the influence of the Idle roll speed on the ring production three
different case studies were simulated following three different speed laws:
 constant (W1);
 linearly descending (W2);
 quadratic descending (W3);
The descending strategy was adopted to help the quality of the ring produced in fact
in the last part of the process if the Idle speed tends to zero the roll gap between the Idle
and the Driver roll became almost constant and the deformation process tends to be
uniform. The result of this strategy is a better quality of the ring in terms of reduced
fishtail and homogeneous ring width. In Figure 4 the designed speed laws are plotted.

Fig (4.4) Speed laws implemented for the first numerical campaign

Fig (4.5) Milling curves modelled for the first numerical campaign

The Driver roll angular speed and the Axial roll speed were set constant and
respectively equal to 3 rad/sec and 0.33 mm/s. Figure 5 reports the milling curves based
on these constrains.

4.2.1 First Numerical Campaign Results

The results were compared to study the set of process parameters that guarantees a good
quality of the ring and reduced loads and energies related with the ring production. In
Table 3 the obtained ring geometries are reported for all the tested cases.

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Fig. (4.6) Fishtail defect

As it can be observed from Table 3, even if the simulations have been stopped
when the desired ring width was reached because this value is imposed by the roll gap
between the Idle and the Driver rolls, the other dimensions of the simulated rings are
slightly different from each other. This is due to an undesired material flow along the
axial direction instead of on the radial direction: this effect generates an irregular ring
height at the end of the process known as fishtail. The fishtail defect for each case study
is plotted in Figure16; the graph underlines a direct correlation between the Idle speed
law and the fishtail defect. Because of its irregular profile the authors propose, in a
previous work [9], to estimate the quality of the ring as an indirect measure of the
external diameter; indeed, the higher the external diameter and the radial ring
deformation, the lower the axial deformation and the fishtail defect. Analyzing the
geometrical results is possible to observe a significate improvement when a descending
trend is imposed; indeed, the ring diameter improves its growth of 7% when a linearly
descending trend is set moreover Figure 6 plots how the fishtail became more flat in
case of descending trend.
The physical comparison between the simulated case studies are showed in
Figure 4.7 where the maximum loads and the energies required for the deformation
process are reported.

Fig (4.7) Maximum load tread Fig (4.8) Energy trad for the
for the idle and the axial rolls. idle, axial and driver rolls.

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As can be observed the different speed laws set for the Idle roll not only affect
the Idle but also the Axial and the Driver roll physical parameters (loads and energy):
in particular, the results underlined a parabolic trend with a minimum achieved for the
W2H1 test for the maximum Axial load reached. On the contrary the maximum Idle
seems to be less affected by the speed laws. The energy values, expressed, in Figure
4.8 underlined an increasing and decreasing trend for the Idle and the Axial roll
respectively; the Driver roll seems to follow a descending trend too with a minimum
recorded for the W2H1 test condition.
By resuming the geometrical and physical results is possible to assert that
imposing a constant value to the Idle and Axial speed (W1H1) leads to a condition
characterized by an higher fishtail, high maximum Axial load, Axial energy and Driver
energy. About the other speed laws tested it is possible to assert that similar results are
measured however a little improvement of the W2H1 test condition is achieved with
respect of W3H1 in terms of maximum Axial load and Driver roll energy that high
affect the process. Based on this evidence the following Axial rolls campaign was
designed taking into account the W2H1 as starting condition.

4.3 Second Numerical Campaign

As in the first campaign in order to study the influence of the Axial roll speed
on the ring production three different case studies were simulated following three
different speed law:
 constant (H1);
 linearly descending (H2);
 quadratic descending (H3);

Fig (4.9) Speed laws implemented Fig (4.10) Milling curves

for the second numerical campaign modelled for the second
numerical campaign

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According to the first campaign the Driver roll angular speed was set equal to 3
rad/s while for the Idle roll speed the linearly decreasing trend (W2 reported in Figure
4.9) was imposed based on the results of the first campaign. Figure 4.10 reports the
milling curves based on the discussed constrain.

4.3.1 Second Numerical Campaign Results

The analysis of results were executed following the same approach executed for
the first campaign.
Therefore in Table 4 and Figure 4.11 the obtained geometries and the fishtail profiles
are reported.

Fig (4.11) Fishtail defect

As can be observed, also for the Axial roll benefits are achieved when the
motion law is not more constant but follows a descending trend. In particular, the W2H2
test condition guarantees with respect to the W2H3 a more flat fishtail and comparable
results in terms of obtained geometry. Unfortunately, despite these benefits some
critical aspects arise in the loads and energy comparison.

Fig (4.12) Maximum load treand for the Fig (4.13) Energy trend for idle,
idle and the axial rolls Axial and driver rolls

Indeed, as reported in Figure 13 and 14 an increasing trend is observed for the

load and the related energy for most of the rolls. In particular, an increment of 70% is

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registered for the maximum Axial load moving from W2H1 to W2H3 process
condition. On the contrary, the maximum Idle load is lower (about 14%). Analyzing
Figure 4.12 similar results can be deduced: an high correlation between the speed trend
and the Axial roll energy; moderate correlation with the Driver roll energy and minor
influence with the Idle roll energy.
The results of the second campaign highlights positive and negative aspect on
the Axial roll speed law influence: when the law starts to have a descending trend a
benefits is registered in terms of ring quality but, as confirmed from the graphs shown
in Figure 4.11 and 4.12, these improvements results in an increasing of the needed
loads and energies. Because the improvements are not proportional (increase the ring
quality costs too much in terms of energy) the W2H1 process condition still represents
the optimum.

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CHAPTER 5
TECHNICAL SPECIFICATIONS

5.1 ADVANTAGES
• It strengthens the metal in high temperatures and provides durability.
• It is a lot more cost effective when compared to the other processes.
• Forging makes it easy to predict how the metal reacts to the process hence
it involves lesser manpower and effort.
• This technique can be applied to all kind of materials and there are lesser
restrictions.

5.2 APPLICATIONS

This rings can be used in many products such as:

• Valves
• Bearings
• Flanges
• Robotics
• Gears
• Couplings
• Machines
• Clutches and drives

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CHAPTER-4

REFLECTION

My internship at the Vishnu forge industries has significantly improved my

knowledge of the workings of the technical worlds and left me with skills that will be
useful throughout my career. Internships are the first professional experiences in the
field and will become a stepping stone to the next work assignment. The experience
in this area is a good preview of my career and future. I learned some important skills
and found out some things about myself. I was immersed with the various product
planning, production, & quality control processes.
Communication is one of the most important professional skills we can
develop. The process of seeking an internship, the work experience itself, and
reflecting afterward, will all contribute to the growth of your communication skills.
Overall, my work experience at was positive. I was very happy with the
amount of things that I have learned and experienced in the 4 weeks of being a Student
Engineer with the company. I believe that Vishvesvaraya technological University
should keep this aspect of the Engineering course as it does provide students with the
experience needed in order to find a job later on.

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CHAPTER-5

CONCLUSION
Vishnu forge industries limited has proved to best and one of the competitive
private sectors. As I have experienced, there is no shortage of expertise, talent,
professionalism and dedication of the work force towards accomplishing the tasks
and targets in meeting delivery of products to its various customer segments. It was
a privilege to be the part of this esteemed organization as an intern and I am fortunate
to have the exposure across most of the departments and its industrial functioning.
It was in overall a good learning and rewarding experience.

DEPARTMENT OF MECHANICAL ENGINEERING, CBIT, KOLAR Page 24