1. MANUFACTURING PRACTICE
PUNE INSTITUTE OF COMPUTER TECHNOLOGY, PUNE – Department of Applied Science
MANUFACTURING PRACTICE
PRESENTATION # 1
SMITHY AND FORGING
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2. PUNE INSTITUTE OF COMPUTER TECHNOLOGY, PUNE – Department of Applied Science Manufacturing Practice
What is Forging?
Forging may be defined as the plastic flow of metal by the application of compressive forces in which a metal is altered in shape permanently without rupture.
Hence, it involves the shaping of metal using localized compressive forces.
The application of heat increases the plasticity of metals thus making it possible to conduct the operations necessary for the fabrication of various shapes of products.
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3. PUNE INSTITUTE OF COMPUTER TECHNOLOGY, PUNE – Department of Applied Science Manufacturing Practice
about Forging…….
Forging is one of the oldest known metalworking processes.
Forged parts can range in weight from less than a kilogram to metric tons.
In modern times, industrial forging is done either with presses or with hammers powered by compressed air, electricity, hydraulics or steam.
These hammers may have reciprocating weights in the thousands of kilograms. Smaller power hammers, 230 kg or less reciprocating weight, and hydraulic presses are common in art smithies as well.
PICT,Pune Presentation # 1: Smithy & Forging
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4. PUNE INSTITUTE OF COMPUTER TECHNOLOGY, PUNE – Department of Applied Science Manufacturing Practice
Types of Forging
Forging processes can be performed at various temperatures
However they are generally classified by whether the metal temperature is above or below the recrystallization temperature.
If the temperature is above the material's recrystallization temperature it is hot forging
If the temperature is below the material's recrystallization temperature it is cold forging
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5. PUNE INSTITUTE OF COMPUTER TECHNOLOGY, PUNE – Department of Applied Science Manufacturing Practice
Advantages of Forging
Forging can produce a piece that is stronger and tough, than an equivalent cast or machined part.
Forged parts show improved strength characteristics.
As forged parts have a high strength to weight ratio, the material required to produce a component is less
Hot forged parts do not require hardening of the material.
Internal defects like segregation, cracks and porosity are eliminated
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6. PUNE INSTITUTE OF COMPUTER TECHNOLOGY, PUNE – Department of Applied Science Manufacturing Practice
Advantages of Forging
Components can be produced to the closer tolerances.
It results in saving in time and material as compare to production of the same component by other manufacturing process.
Forged components has ability to withstand higher loads during the service
Materials like iron and steel, which are widely used for manufacturing, can be easily hot forged.
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7. Disadvantages of Forging
PUNE INSTITUTE OF COMPUTER TECHNOLOGY, PUNE – Department of Applied Science Manufacturing Practice
Disadvantages of Forging
Brittle material like cast iron can not be forged.
Cost of forging dies are high
Complex shapes can not be easily forged. They are generally produced by casting process.
The process is not suitable for mass production.
To relieve the internal stresses in the material, Cold forging always be followed by hardening process.
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8. Basic Operations of Forgings
PUNE INSTITUTE OF COMPUTER TECHNOLOGY, PUNE – Department of Applied Science Manufacturing Practice
Basic Operations of Forgings
Upsetting
When a piece of raw material is worked in such a way that its length is shortened and either or both its thickness and width increased, the piece is said to be upset and operation is called as upsetting
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9. Basic Operations of Forgings
PUNE INSTITUTE OF COMPUTER TECHNOLOGY, PUNE – Department of Applied Science Manufacturing Practice
Basic Operations of Forgings
Heading…..
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10. Basic Operations of Forgings
PUNE INSTITUTE OF COMPUTER TECHNOLOGY, PUNE – Department of Applied Science Manufacturing Practice
Basic Operations of Forgings
Fullering
It is the operation of reducing the raw material between the two ends at the central place, so as to increase its length.
PICT,Pune Presentation # 1: Smithy & Forging
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11. Basic Operations of Forgings
PUNE INSTITUTE OF COMPUTER TECHNOLOGY, PUNE – Department of Applied Science Manufacturing Practice
Basic Operations of Forgings
Edging
The function of edging or rolling operation is to distribute the metal longitudinally by moving metal from the portion of the raw material where it is excess to the portion where it is deficient.
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12. Basic Operations of Forgings
PUNE INSTITUTE OF COMPUTER TECHNOLOGY, PUNE – Department of Applied Science Manufacturing Practice
Basic Operations of Forgings
Drawing
The operation by which reduction in size of the material at only one end, is termed as Drawing
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13. Operations of Forgings
PUNE INSTITUTE OF COMPUTER TECHNOLOGY, PUNE – Department of Applied Science Manufacturing Practice
Operations of Forgings
PICT,Pune Presentation # 1: Smithy & Forging
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14. Methods of Hot Forging Drop Forging
PUNE INSTITUTE OF COMPUTER TECHNOLOGY, PUNE – Department of Applied Science Manufacturing Practice
Methods of Hot Forging
Drop Forging
This process is used for mass production of identical parts
This operation is done in closed impression dies by means of drop hammers.
The die is made of two halves
The upper die is attached to the hammer and lower is attached to the anvil
The heated raw metal is kept on lower die and the top die is allowed to fall suddenly on the lower die.
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15. Methods of Hot Forging Diagram of Drop Forging Press
PUNE INSTITUTE OF COMPUTER TECHNOLOGY, PUNE – Department of Applied Science Manufacturing Practice
Methods of Hot Forging
Diagram of Drop Forging Press
The drop forging method is suitable to manufacture car axles, connecting rods of I C Engine, crank shafts, leaf springs, crane hooks, jet engine blades etc.
PICT,Pune Presentation # 1: Smithy & Forging
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16. Methods of Hot Forging Press Forging
PUNE INSTITUTE OF COMPUTER TECHNOLOGY, PUNE – Department of Applied Science Manufacturing Practice
Methods of Hot Forging
Press Forging
Hammering action is relatively slow squeezing instead of delivery heavy blows
It is similar to drop forging only in this case the lower movement of the ram / Upper die, is slow.
It is more accurate method than drop forging as in press forging metal penetrates deeply as it gives the time to flow the metal.
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17. Methods of Hot Forging Diagram of Forging Press
PUNE INSTITUTE OF COMPUTER TECHNOLOGY, PUNE – Department of Applied Science Workshop Practice
Methods of Hot Forging
Diagram of Forging Press
The drop forging method is suitable to manufacture large lever flanges, propellers, hollow bodies, railway wheel disks, panel etc.
Hydraulically Operated Press
Mechanically Operated Press
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18. Methods of Hot Forging Actual Diagram of Press Forging
PUNE INSTITUTE OF COMPUTER TECHNOLOGY, PUNE – Department of Applied Science Manufacturing Practice
Methods of Hot Forging
Actual Diagram of Press Forging
PICT,Pune Presentation # 1: Smithy & Forging
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19. Video of Hot Forging operations
PUNE INSTITUTE OF COMPUTER TECHNOLOGY, PUNE – Department of Applied Science Manufacturing Practice
Video of Hot Forging operations
PICT,Pune Presentation # 1: Smithy & Forging
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20. Video of Hot Forging of Basket Twist
PUNE INSTITUTE OF COMPUTER TECHNOLOGY, PUNE – Department of Applied Science Manufacturing Practice
Video of Hot Forging of Basket Twist
PICT,Pune Presentation # 1: Smithy & Forging
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Presentation # 1 : Smithy & Forging

21. Methods of Cold Forgings
PUNE INSTITUTE OF COMPUTER TECHNOLOGY, PUNE – Department of Applied Science Manufacturing Practice
Methods of Cold Forgings
Cold Heading
The end of the metal piece which is at room temperature (i.e. temperature below its recrystallization temperature) is given the desired shaped
PICT,Pune Presentation # 1: Smithy & Forging
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Presentation # 1 : Smithy & Forging

22. Methods of Cold Forgings
PUNE INSTITUTE OF COMPUTER TECHNOLOGY, PUNE – Department of Applied Science Manufacturing Practice
Methods of Cold Forgings
Cold Forming / Rolling
The end of the metal piece which is at room temperature (i.e. temperature below its recrystallization temperature) is given the desired shaped
PICT,Pune Presentation # 1: Smithy & Forging
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Presentation # 1 : Smithy & Forging

23. Video of Cold forming of sheet metal parts of Sheet Metal
PUNE INSTITUTE OF COMPUTER TECHNOLOGY, PUNE – Department of Applied Science Manufacturing Practice
Video of Cold forming of sheet metal parts of Sheet Metal
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24. PUNE INSTITUTE OF COMPUTER TECHNOLOGY, PUNE – Department of Applied Science Manufacturing Practice
End of Presentation 1
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Presentation # 1 : Smithy & Forging

25. What are different types of forgings?
PUNE INSTITUTE OF COMPUTER TECHNOLOGY, PUNE – Department of Applied Science Manufacturing Practice
Questions
What is Forging ?
What are different types of forgings?
Explain in detail the basic operations of forgings?
Explain in detail the operations of Hot Forgings ?
Explain in detail the operations of Cold Forgings ?
What are the advantages and disadvantages of forgings ?
PICT,Pune Presentation # 1: Smithy & Forging
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Presentation # 1 : Smithy & Forging