No Slide Title
WHAT IS FORGING?Forging is the process by which metal is heated
and is shaped by plastic deformation by suitably applying
compressive force. Forging refines the grain structure and improves
physical properties of the metal. With proper design, the grain
flow can be oriented in the direction of principal stresses
encountered in actual use. Grain flow is the direction of the
pattern that the crystals take during plastic deformation. Physical
properties (such as strength, ductility and toughness) are much
better in a forging than in the base metal, which has, crystals
randomly oriented. .
MAJOR TASKS OF THE PROJECT
DESIGN & FABRICATE A PROTOTYPE OF A FORGING PART FOR AN
AUTOMOTIVE INDUSTRY BY REVERSE ENGINEERING/CAD/CAM/CAE.Rabia
Siddiqui, Sanna Irfan, Sheheryar Mohsin , Sara Binte Ali Advisor:
MR. Ali ZulqarnainDepartment of Industrial & Manufacturing
EngineeringNED University of Engineering & Technology
AcknowledgementsContinued collaboration of NED University of
Engineering and Technology and TAHA ENGINEERING is highly
acknowledged.DIE CALCULATIONS
NON TRADITIONAL MACHINING:STRESS ANALYSIS(ANSYS)
CNC machining centreConventional machining EDM wire
cutElectrodePrototyping by EDMPart modellingby using
PRO-EScanning
Process parametersPunchDieElectrode
Material Selection(die Block)Material selected is chromium type
tool steel(H-13) as it contains 1%Vanadium which helps in
increasing the forgeability.Components
Weight (%)
C
0.32 - 0.4
Cr
5.013 - 5.25
Fe
Min 90.95
Si
1
V
1
Composition of H-13Entity Relationship DiagramL = l + 3 h [Ref.
Book: PC Sharma (Page: 180)] Where, L = length of die block l =
total length of impression = 97.6mm (Ref. Part drawing) h = maximum
depth of impression = 11.525mm (Ref. Part drawing) L = 97.6 + 3 X
11.525 Therefore, L = 132.15 mm Selected size = 150 mm (Standard
size available in market)h (mm)H (mm)61001012540200100315Size of
Die Block(Length)Height of Die Block(Length)
Rated Size of HammerRated Size(lb)Power DropMax.
Energy(Ft-lb)Gravity DropMax.
Energy(Ft-lb)100011,1003850150016,7005870200022,5008830250028,50011,320300034,40014,200400046,00019,400500058,00024,700650070,00030,000800094,00041,60010,000118,00052,00012,000142,00016,000190,00020,000240,00025,000300,000SELECTION
OF ELECTRODE MATERIALELECTRODE MATERIALFORMCORNER WEAR RATIO IN
FINISHINGEND WEAR RATIO IN ROUGHINGRELATIVE COSTMACHINABILITY
RATINGCOPPERBar, rod, sheet, wire, tube, forgings,
stampings1:12:1MediumGoodProcess ParametersCurrent in each
spark
Frequency of discharge
Spark gap
Dielectric fluid
Depth setting
PolarityCNC MACHINING
Tool Path GenerationMACHINING PROGRAM PERAMETERSNC Sequence name
: FinishingOperation name : CNC MillingWork Cell name : machine
01Work Cell type : MillAxis Type : 3-AxisCutting Time : 57.75
minNCL File Name : FinishingPOST_PROCESSOR---P14 Tool_ID : Tool
0001Diameter : 8mmDiameter : 6mmCut_Type : ConventionalStep_Depth :
0.3mmStep_0ver : 10mmCut_Feed : 1800 mm/minSpindle_Speed : 2000
rev/minCoolant : OnNC SEQUENCE PARAMETERS
Finding allowable working stress: from the analysis:Sw = Sm /
F.O.S stresses generated=Where; 600Psi
