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Forging and casting technology

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Forging and casting technology

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