Forging and Casting Technology Karan Vohra- B.Tech IIT-BHUDepartment of Metallurgical Engineering
A process of providing shape ora design to a metal/alloy by beating or applying pressure through Hammers below melting point. Forging Technology
Methods of Forging Impression / Closed Die Forging Highly flexible process (few ounces to 25 tons) Higher dimensional accuracy Ability to attain more complex shapes carbon and alloy steels, tool steels, stainless, aluminium and copper alloys, and certain titanium alloys. Cold Die Forging Room temp- few hundred degree Celsius Lower-alloy, carbon steels, stainless steel selected aluminium alloys, brass and bronze. Economic: high strength, close tolerances and volume production Application: automotive steering and suspension parts, antilock-braking systems, hardware, defence components Size constraint
Foundry Technology A Fabrication technique which uses a model of the desired design specimen (pattern) to create a cavity in a suitable moulding material which in turn is filled by the liquid metal to obtain the product Casting.
Work flow in Sand Casting Foundries WORLD OF STEEL
Comparison between Forging and Casting The choice of operation depends on the design, application and the cost involved.
Advantages Forging Casting Good Mechanical Properties (yield strength, ductility, toughness) Reliability (for critical parts) No liquid metal treatment Complex, intricate shapes in a single step Reduces cost of machining Flexible process Isotropy in properties High production rate WORLD OF STEEL
Disadvantages Forging Casting Low strength (requires further heat treatment) Prone to defects:shrinkagepinholesmisrun Complex process Involves higher cost Shape limited when undercuts or cored sections are required Requires lots of considerations to avoid defects WORLD OF STEEL
Major defects in Forgings and Castings WORLD OF STEEL