Defects in forging

video1.swf

Mahander Pratap Singh

(071577)
Munish kumar
(071425)
 What is forging
Forging can be defined as the controlled plastic deformation of
metals at elevated temperatures in to a predetermined size or
shape using compressive forces exerted, through some type of
die, by a hammer, a press or upsetting machine.

Forging enhances the mechanical properties of metals and

improves the grain flow, which in turn increases the strength and
toughness of the forged components.
 
 Types of forging
• Closed die forging • Open die forging
 Forging Temperatures
Forging Temperature oC
Sr.No. Metal / Alloy
Starting Finishing

Mild steel
01 1300 800

Wrought iron
02 1275 900

Medium carbon steel

03 1250 750

High carbon steel

04 1150 825

Copper, brass and bronze

05 950 600

Aluminium and magnesium alloys

06 500 350
 DEFECTS IN FORGING
• Defective structure of metal; Reason – defective original metal.
• Presence of cold shuts or cracks at corners; Reason – improper
forging and faulty die design.
• Incomplete component; Reason – less metal used, faulty die design
and inadequate metal flow.
• Mismatched forging; Reason – die halves not properly aligned.
• Burnt and overheated metal; Reason – improper heating.
• Fiber flow lines or grain flow lines disconnected; Reason – very
rapid plastic flow of metal.
• Scale pits; Reason – formed by squeezing of scale into metal during
forging.
• Oversize components; Reason – worn out dies, incorrect dies.
 Types of defects
(Samrat forging)
• Unfill
• Mismatch
• Cracks
• Double strokes
• Overheating
• Lapping
• Undersize
Quality measurements of
products.
 CRACKS
• Causes:
 Surface cracking can occur as a result of excessive working of the s/c at too low tempr.

 Can be due to hot shortness .

• Remedial measures:
 LAPPING
• Causes:
 When metal flows past part of the die cavity that has already been filled or that is only partly filled becoz
the metal failed to fill in due to ssharp corner
 Due to excessicve chilling
 Due to high friction.
 Too small die radius .

• Remedial measures:
 UNFILL
• Causes:

• Remedial measures:
 Cracking at flash
• Causes:
 When the flash is thin.

• Remedial measures:
 Increase the flash thickness of the metal
 By relocating the flash to a less critical region of the forging.
 PITTING
• Causes:

• Remedial measures:
 Out comes of the project
• Understand the whole process of forging.
• Comes to understand various defects related to forging
process.
• Tried to find the possible causes of defects at samrat forging.
• Tried to find out the possible remidial measures.