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Forging and casting technology

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  • 1. Forging and Casting Technology
    Karan Vohra- B.Tech IIT-BHUDepartment of Metallurgical Engineering
  • 2. A process of providing shape ora design to a metal/alloy by beating or applying pressure through Hammers below melting
    point.
    Forging Technology
  • 3. 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
  • 4. 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.
  • 5. Work flow in Sand Casting Foundries
    WORLD OF STEEL
  • 6. WORLD OF STEEL
  • 7. Comparison between Forging and Casting
    The choice of operation depends on the design, application and the cost involved.
  • 8. 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
  • 9. 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
  • 10. Major defects in Forgings and Castings
    WORLD OF STEEL