The document is a study report on the forging process, including its techniques, mechanisms, and applications in various industries such as automotive and aerospace. It details the phases of forging, the equipment used, and explores the manufacturing of crane wheels through closed die forging. Additionally, the report addresses potential defects in forgings and their implications.

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A
FINAL/THIRD YEAR
MECHANICAL/ CIVIL ENGINNERING
PROJECT REPORT ON
A STUDY OF FORGINGS
ITS TECHNIQUES
AND MECHANISMS

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1. ABSTRACT
The term “Forging” is applied to processes in which a piece of metal is worked in a machine
to the desired shape by plastic deformation of the starting stock. The energy that promotes
deformation is applied by a hammer, press, up-setter or ring roller, either alone or in
combination. The shape is imparted by the tools that contact the work piece and by careful
control of the deformation process. A forging is produced in three distinct phases: stock
preparation in the form of blooms, billets, bar or ingots; plastic deformation of the metal
component to rough, close tolerance or net shape in one of the forging processes; and
appropriate secondary operations
Forged metal components are used in wide range of environment where high strength
and reliability are important considerations. The use of forging is to reduce material wastage
and machining time, avoids complex machining operations and for mass production. Forged
components find application in the automobile/automotive industry and in aerospace, aircraft,
railroad, and mining equipment.
Metal forging process is governed by many factors such as friction, complexity of
parts, die shape and temperature of die and billet. In this study we are going to learn about the
principles of material selection, heat treatment, and the design calculations, which is involved
in forging of metal
This project is a study of the forging process, forgings defects, the forging machines
and their applications. In this project we also consider the manufacturing of crane wheels
through the closed die forging process in which metal is plastically reshaped using dies. This
involves the steps like design and material selection based on its properties. Machinery
equipment’s used in forging are pneumatic hammer forging machines, furnaces, dies, band
saw machines etc. Closed die forging process is used to obtain the final product in close
tolerance. The furnace is the main equipment in which the billet is preheated to a temperature
of 1200 degrees centigrade and then forged into required shape. It offers a high strength-to-
weight ratio, toughness, and resistance to impact and fatigue.

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7. DEFECTS IN FORGINGS
Table 7.1: Forgings Defects and corresponding effects