FORGING OPERATIONS,
CASTING DEFECTS
RISER,WIRE DRAWING
AND EXTRUSION
FORGING
Definition: A manufacturing process involving shaping
of metal at a temperature near recrystallization
temperature, using compressive forces delivered
through a hammer (often a power hammer).
Types:
ng
ki
or
Above
ng
W Below ki
ot Recrystallization Recrystallization or
H
Temperature Temperature W
d
ol
C
FORGING OPERATIONS
Forgiving desired shape to the workpiece, one or more of the
following processes should be used.
1. Upsetting
2. Drawing out or drawing down
3. Cutting
4. Bending
5. Punching & Drifting
6. Setting down & finishing
7. Forge Welding
1.UPSETTING / JUMPING /HEADING
Process of increasing cross
section of the workpiece by
corresponding decrease in its
length.
Metal heated till it acquires
plastic stage(becomes soft
enough for deformation)
Ifa bar length which is not to
be jumped is cooled abruptly
by quenching in water.
2.DRAWING OUT / DRAWING DOWN
Reverse of Upsetting
Length increases ; width decreases
Thepre-determined length of the bar is heated to
the plastic state, followed by cooling of the
unwanted length for drawing by sudden quenching
in water.
3.CUTTING
This
solves the purpose of
removing the extra length
(and other dimensions),
before finishing the job.
Hotand cold chisels are
used for cutting.
4.BENDING
Bending of bars, flats and
other similar material to
produce bent shapes such
as angles, ovals and
circles.
5.PUNCHING AND DRIFTING
Punching is a process of producing
holes by forcing the punch through
the work.
InDrifting, a drift is made to pass
through the punched hole to
produce a finished hole of the
required size.
6.SETTING DOWN AND FINISHING
Setting
Down: Operation through
which the round corner is
removed, to make it square, by
means of Set Hammer.
Finishing:
Operation through which
the unevenness of a flat surface is
removed by means of a flatter.
7.FORGE WELDING
Two pieces of same metal which are to be
joined together are heated to white hot
temperature where both of them fuse into a
single object.
Temperature has an important role; incorrect
temperature will spoil the joint. If higher than
required, the piece will melt and disturb the
shape; if lower, the joint wouldn’t be
established.q
CASTING DEFECTS
Factors responsible for production of defects in the casting:
1. Design of casting
2. Design of pattern equipment
3. Moulding and core-making equipment
4. Mould and core materials
5. Gating and riser
6. Moulding and core-making techniques
7. Melting and pouring
8. Metal composition
Following slides will display what all defects can occur in the casting, their causes &
possible solutions
1.BLOW HOLES
Description: cavities appearing on the surface of
the casting.
Reason:
Excess moisture in moulding sand
Cores not adequately vented(expelled) off air
Remedies:
Control moisture content
Bake cores properly
2.POROSITY
Description:
Minute cavities of trapped gases
Too small to be viewed by naked eyes (X-rays
required)
Reason:
Gases trapped during solidification
Moisture in air, mould or furnace
More pronounced with high pouring temperature &
slow solidification
Less flux used
Remedies:
Regulate pouring temperature
Increase flux proportion
3.VOLUMETRIC SHRINKAGE
Description: During
solidification, a decrease in
volume is observed
Reason:
Improper cooling
Faulty gating system
Remedies: Ensure proper
gating & risering system
4.MISRUN & COLD SHUTS
Description: A kind of incomplete
casting
Reason:
Faulty design
Faulty gating system
Lack of fluidity in molten metal
Remedies:
Modify design
Modify gating system
Adjust proper pouring temperature in
order to ensure fluidity
5. INCLUSIONS
Description: Any separate non
metallic foreign material present
in the cast metal
Reason:
Faulty gating
Faulty Pouring
Remedies:
Modify gating system
Improve pouring to minimise
turbulence
6.HOT TEAR / HOT CRACKS /PULLS
Description: Cracks developed in the interior/exterior of the cast
Reason:
Low strength of metal after solidification ; unable to oppose solid shrinkage.
Faulty design; exceptionally high stress at certain points
Remedies:
Modify design
7.METAL PENETRATION
Description: Occurs as a rough &
uneven external surface on the
casting
Reason:
Large grain sized sand used
Moulding sand is of low strength
Pouring temperature of metal is too high
Remedies:
Use sand having finer grains
Suitably adjust the pouring temperature
8.Wrapage
Description: Undesirable deformation in the casting, occurring
during or after solidification
Reason: Poor design; Non uniform wall thickness
Remedies: Modify casting design
RISER
A passage made in the Cope through which the
molten metal rises after the mould is filled up.
Advantage:
1. During pouring, allows air, steam & gases to go out
of the mould.
2. Observing the riser filling, ensures the complete
filling of the mould.
3. A reservoir to feed the molten metal to the
casting to compensate the shrinkage during
solidification.
TYPES OF RISERS
WIRE DRAWING
WIRE DRAWING
EXTRUSION- DIRECT AND INDIRECT
DIRECT
INDIRECT
FORGING TOOLS
FORGING TOOLS
HAMMERS
CHISELS
TONGS
DRIFTS
FULLERS
SWAGES
FLATTERS AND SET HAMMERS
