Introduction

Forging is the process by which metal is heated and is shaped by plastic deformation by suitably applying compressive force. Usually the compressive force is in the form of hammer blows using a power hammer or a press. 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.

Forgings are consistent from piece to piece, without any of the porosity, voids, inclusions and other defects. !hus, finishing operations such as machining do not e"pose voids, because there aren#t any. $lso coating operations such as plating or painting are straightforward due to a good surface, which needs very little preparation. Forgings yield parts that have high strength to weight ratio%thus are often used in the design of aircraft frame members. $ Forged metal can result in the following & 'ncrease length, decrease cross%section, called drawing out the metal. & (ecrease length, increase cross%section, called upsetting the metal. & )hange length, change cross%section, by squeezing in closed impression dies. !his results in favorable grain flow for strong parts

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Common Forging Processes

!he metal can be forged hot (above recrystallization temperatures or cold. Open Die Forgings / Hand Forgings* +pen die forgings or hand forgings are made with repeated blows in an open die, where the operator manipulates the workpiece in the die. !he finished product is a rough appro"imation of the die. !his is what a traditional blacksmith does, and is an old manufacturing process. Impression Die Forgings / Precision Forgings* 'mpression die forgings and precision forgings are further refinements of the blocker forgings. !he finished part more closely resembles the die impression. Design Consideration* & Parting surface should be along a single plane if possible, else follow the contour of the part. !he parting surface should be through the center of the part, not near the upper or lower edges. 'f the parting line cannot be on a single plane, then it is good practice to use symmetry of the design to minimi,e the side thrust forces. $ny point on the parting surface should be less than -./ from the principal parting plane. & $s in most forming processes, use of undercuts should be avoided, as these will make the removal of the part difficult, if not impossible. & 0ecommended draft angles are described in the following table. Material $luminum )opper $lloys (3rass 5teel 5tainless 5teel Draft Angle (/ 1%2 1%4 .%.%6

& Generous fillets and radius should be provided to aid in material flow during the forging process. 5harp corners are stress%risers in the forgings, as well as make the dies weak in service. 0ecommended minimum radiuses are described in the following table. Height of Protrusion mm (in 72.. (1.. 2. (7.1 .1 (2.1 711 (9.1 911 (78 Min. Corner Radius mm (in 7.. (1.18 4 (1.72 . (1.2 8.2. (1.2. 22 (1.6-. Min. Fillet Radius mm (in . (1.2 8.2. (1.2. 71 (1.9 71 (1.9 .1 (2.1

& 0ibs should be not be high or narrow, this makes it difficult for the material to flow. Tolerances* & Dimension tolerances are usually positive and are appro"imately 1.4 : of the dimension, rounded off to the ne"t higher 1.. mm (1.121 in . & Die wear tolerances are lateral tolerances (parallel to the parting plane and are roughly ;1.2 : for )opper alloys to ;1.. : for $luminum and 5teel. & Die closure tolerances are in the direction of opening and closing, and range from 7 mm (1.191 inch for small forgings, die pro<ection area = 7.1 cm 2 (24 in2 , to 8.2. mm (1.2. inch for large forgings, die pro<ection area > 8.11 cm2 (711 in2 . & Die match tolerances are to allow for shift in the upper die with respect to the lower die. !his is weight based and is shown in the the following table. Finished Forging eight !rimmed kg (lb Material = 71 (= 22 = .1 (= 771 > .11 (> 7711

Die Match Tolerance mm (in $luminum, )opper $lloys, 5teel 5tainless 5teel, !itanium 1.-. (1.141 7.2. (1.1.1 7.-. (1.1-1 2.. (1.711 . (1.211 8.. (1.281

& Flash tolerance is the amount of acceptable flash after the trimming operation.

!his is weight based and is shown in the following table. Finished Forging eight !rimmed kg (lb Material = 71 (= 22 = .1 (= 771 Flash Tolerance mm (in $luminum, )opper $lloys, 5teel 5tainless 5teel, !itanium 1.6 (1.142 7.8 (1.189 4.2. (1.72. . (1.2 71 (1.9 72.. (1.. > .11 (> 7711

$ proper lubricant is necessary for making good forgings. !he lubricant is useful in preventing sticking of the workpiece to the die, and also acts as a thermal insulator to help reduce die wear. Press Forgings* Press forging use a slow s?uee,ing action of a press, to transfer a great amount of compressive force to the workpiece. Unlike an open%die forging where multiple blows transfer the compressive energy to the outside of the product, press forging transfers the force uniformly to the bulk of the material. !his results in uniform material properties and is necessary for large weight forgings. Parts made with this process can be ?uite large as much as 72. kg (281 lb and 4m (71 feet long. !pset Forgings* Upset forging increases cross%section by compressing the length, this is used in making heads on bolts and fasteners, valves and other similar parts.

Roll Forgings* 'n roll forging, a bar stock, round or flat is placed between die rollers which reduces the cross%section and increases the length to form parts such as a"les, leaf springs etc. !his is essentially a form of draw forging. "#aging* 5waging % a tube or rod is forced inside a die and the diameter is reduced as the cylindrical ob<ect is fed. !he die hammers the diameter and causes the metal to flow inward causing the outer diameter of the tube or the rod to take the shape of the die. $et "hape / $ear%$et "hape Forging* 'n net shape or near%net shape forging, forging results in wastage of material in the form of material flash and subse?uent machining operations. !his wastage can be as high as -1 : for gear blanks, and even @1; : in the case of aircraft structural parts. Aet%shape and near%net%shape

processes minimi,e the waste by making precision dies, producing parts with very little draft angle (less than 7/ . !hese types of processes often eliminate or reduce machining. !he processes are ?uite expensive in terms of tooling and the capital e"penditure re?uired. !hus, these processes can be only <ustified for current processes that are very wasteful where the material savings will pay for the significant increase in tooling costs.

Ma&plus 'nterprise Closed Die forging( Drop forging( Hot forging( !pset forging components from India Manufacturer e&porter closed die forging ) drop forging / hot forging * ( upset forging from Car+on steel( allo, steel and stainless steel.
$boutUs Introduction 'nfrastructure Process Products Buality )ontact

We are 'ndia based manufacturer and e"porter of Closed die forging ) drop forging / Hot forging * for car+on steel( allo, steel and stainless steel. We manufacture ?uality drop forging components ) hot forging * - !pset forging as per your specification and samples . +ur main product line includes hot forgings and upset forgings for automobile industry, agricultural implements, flanges and pipe fittings, electric transmission C pole line parts, earth mover parts. We also supply customi,ed forgings as per buyers drawings C samples. We can handle parts from 711 grams to 7. kilograms, moreover well e?uipped advanced forge shop, die shop, metal testing laboratory, )utting D 5hear shop, an efficient heat treatment facility with machine shop, ensures fast delivery of your part and also making us a one%stop source for all your hot forging, upset forging needs. We work with a sole ob<ective of helping your business with customi,ed drop forging C hot forging C upset forging solutions. We have built a reputation of Up

being a forward thinking, plan%design%build company, committed to our ?uality ob<ective of satisfying our clients to the fullest e"tent. We have an optimum mi" of manpower and sophisticated technology to provide you customi,ed forgings. With seasoned e"pertise in forging industry, we know how to get the <ob done. We believe in delivering ?uality products , on schedule at a competitive price and We believe in developing and forging all business relationship on the foundation of Buality, Eonesty and !rust. Please visit other sections of our website to gather more details and incase of your re?uirements for hot forgings using drop forging method or upset forging please feel free to contact us. A+out !s We are manufacturer of closed die forging, upset forging. We adopt drop forging and hot forging methods to forge car+on steel( allo, steel and stainless steel.

Fa"plus Gnterprise H forgings I has a long standing reputation in forging industry. We stand with our commitment to ?uality, innovation and customer orientation. Buality forged products coupled with delightful forged relationship with our clientele have made us leader in our industry. +ur customers pose high faith in us and we take e"tra efforts to match their e"pectations. We deal in closed die forgings of carbon, alloys and stainless steel, products ranging from 7 to 7. JilogramCPiece by weight.

Gstablished in 7@@., the management and their team comprises of dedicated professionals from the field of engineering and business management. !his team derives ideological and financial support from promoters who are established and e"perienced in industry and business. 'nitially we started forging auto parts and flanges, within two years of business the market has started accepting us as a reliable supplier of forgings. $fter about 8 years of local market e"perience we looked toward e"panding our market reach by e"porting our products. )urrently we e"port our products Gurope, U5$. Up

'n our glorious <ourney, we have gradually moved up the success ladder, thanks to sound management system, ethical practices and promoters# acumen in the industry. We have e"panded ourselves ?ualitatively and ?uantitatively and today we cater to the needs of varied customers falling in diverse range of industries such as automotive ancillaries, engine manufacturing, agricultural implements, electric transmission parts and others. 5trictly dedicated to regimented practices, we have always catered to orders of different magnitudes, shapes and si,es with specific time frame and ?uality re?uirements.

We are situated at 0a<kot HGu<arat 5tate% 'ndia I , the city well known for top ?uality engineering products across 'ndia. !he city is well connected with road, rail and air. 't is about 9. minutes away from Fumbai via $ir route. Foreover well known ports like Jandla port, Fundra port is also about 2.1 Jms from our city.

Forging Infrasturcture
+ur infrastructure consist of advanced forge shop, die shop, metal testing laboratory, )utting D 5hear shop, an efficient heat treatment facility with machine shop, ensures fast delivery of your part and also making us a one%stop source for all your forging needs.

Forge shop consist of (rop Eammer (2 !on D 7 ton , Pusher type furnace H.11 Jgs per EourI ,Fechanical Power Press, Eeat !reatment Furnace bo" type. (ie shop is e?uipped with Kertical Filling machine, Glectro discharge, Lathe machines, shaping C drilling machines , air compressors, die grinders, welding machines. )utting shop is e?uipped with 3and%saw Fachines, 3illet 5hearing Fachines. Buality control e?uipments includes megna flu" for crack detection, Kerniers, ,3evel protector , Universal testing machine, impact !est 'mpact test e?uipments, 3rinnelC0ockwell hardness testers. Up

'ncase of finished products or machined parts, we have tie%up with very competent machining suppliers with large fleet of latest )A) Fachines and each machined part is thoroughly inspected for dimensional accuracy. 0adiography test C ultrasonic test is outsourced to the best and most competent units identified by us.

Forging Process
!he process of forgings starts from designing facility through both, )omputers and Fanually facilitates us preparing the best modeling for part and tooling development. Dies - Tooling $n 'n%house (ie%shop e?uips us for fabricating all types of dies and tooling, using KF) , lathes and other tools. (ies are produced using Wooden Pattern Graphite Glectrode. Full sets of templates are fitted on sinking of the die for rigid dimensional checks and inspection. Ra# Materials Faterials is procured from reputable approved 5teel Fills in form of )ast 3illets, 3looms, 0olled 3illets etc. , in various 5i,e as per the re?uirement of the final product. 0aw Faterials inward process automatically checks for the ?uality of the Faterial. Faterials of different types are stored separately with color codes marked, to Facilitate full traceability and avoid material mi"%ups. Cutting Fost cutting of raw material is done with the help of 5hearing Fachines and 3and%5aw Fachines. )olor codes are marked on )ut pieces and are stacked separately with a banner fi"ed over each stack so as to identify the materials grade and also the final product to which they are meant. Up

Heating )ut pieces are heated in Pusher type forging Furnaces fitted with !emperature )ontroller. !he pieces are carried to the forging hammers through over%head traveling Fono 0ails. forging( Coining - Trimming !he process of forging is carried out on Pneumatic forging Eammers. !he metal is shaped to a part by Eammering the hot cut piece between the !op and the 3ottom dies fi"ed on the Eammer. !he finished product through this process is much more reliable for strength and ?uality than a similar product produced by casting, pressing or machining. Post forging Operations (epending upon the specific re?uirements of the end use of forged components, forgings undergo further processes such as Eeat !reatment, 5hot 3lasting, Fagnaflu" crack detection. etc. We have an 'n%Eouse facilities for these processes. Machining We are situated at the place where we have a number of ancillaries engaged in doing the machining <obs. Whenever, re?uired we can out source )A) Fachining, (rilling, !hreading, )apping and Grinding etc., from your ?uality% approved ancillaries. .ualit, Assurance Buality checks are inbuilt in the processes to maintain complete control at each stage of the cycle. 't begins with receipt of raw material, die development, cutting, forging which includes hot inspection, secondary operations and final inspection. 5amples are checked for dimensional accuracy and metallurgical soundness. 5amples of hot forgings are inspected at intervals for visual forging defect and dimensional accuracy. 711: crack detection is carried out on

magnaflu" machine and hardness is finally tested to meet with the re?uirements.

Hot - !pset Forging Products

Generally the forging industry don#t limited themselves to a fi"ed product line, but rather make a selection of products on the basis of the infrastructural facilities which one have. Ao doubt that generally each forging unit speciali,e in forging some parts due to their e"perience. We manufacture hot forging C upset forging using carbon, alloy and stainless steel from 711 grams to 7. kilograms Hin some cases the weight may reduce or increase to some e"tent due to nature or comple"ity of designsI. or samples. condition. Automo+ile Components * +ur flagship products when we entered forging business include auto part range. Eot forging auto parts includes u < cross, steering yokes, a"el stub, gear blanks, connecting rods, propeller shaft components, forks, rocker arm , tow ball, crankshaft, compressor crankshaft, camshaft, gear components, clutch forks, tractor parts. We never limit ourselves to parts which we manufacture. We supply customi,ed forged parts as per buyers drawings and samples. Flanges - Fittings / +ur product range also includes various kind of flanges H forged or machined I and pipe fittings. +ur range includes weld%neck, slip on, threaded, socket weld, lap <oint, blind. !he diameter si,e of flanges 7C2M % .MA3. Fittings include Glbows, ! Noints, O Noints, )ouplings. !he diameter si,e which we can handle is 7C9M % 2MA3. !he material standards which we follows are $5!F, ('A, N'5, G+5!, etc. 'lectric Transmission Parts / Pole 0ine Parts / We also manufacture pole line accessories which includes ball clevis, anchor shackle, socket clevis, clevis eye, socket eye, hook, suspension bracket, arching horn, dead end pin H steel e suppl, closed die( upset forging )drop forging/ hot forging* or upset forging products as per ,our specification e suppl, forging in forged ( semi%forged or finished Up

clamps I, bolt hook, horn holder. Foreover we always manufacture parts to your specification C samples. 'arth Mo1er Parts / We also manufacture earth mover HN)3I teeth point and side cutter. !pset forging / Upset forging, also called hot heading, is a process by which the cross%sectional si,e of a bar is increased, either at an end or at some point along its length. 't is done on specially designed upsetting machines, using closed dies to control si,e and shape. We manufacture upset forged products as per buyers drawings and samples. We also supply hot forge C cold forged fasteners. .ualit, Buality % $ commitment, $ habit, $ routine, $ way to growth is how we define it. Buality is the only factor in todays world which can decide the growth of any business organi,ation. 'n order to grow and have e"ponential growth rate one needs to provide consistent ?uality at reasonable price. We at Fa"plus understand this and always follow it, we always believe in delivering products which surpass customers e"pectations. Buality checks are inbuilt in the process to maintain complete control at every stage of forging cycle. 0aw material selection, die development, cutting and forging processes are carried out in pre%specified fashion. Gvery prototype and parts batch go through rigorous ?uality checks. 5amples are checked for dimensional accuracy and metallurgical soundness. 5amples of hot forgings are inspected at regular intervals for visual forging defects and dimensional accuracy. When re?uired, 711: crack detection is carried out on magnaflu" machines and hardness is finally tested to meet with the re?uirements. Foreover continuous training of our technical staff is also undertaken from reputed institutes in order to know latest innovations in our industry and we always try to improve our production process in order to increase ?uality and efficiency as well as to cut down production cost. Up

Contact For $ll your closed die forging C upset forging re?uirements H drop forging C hot forging I for carbon steel, alloy steel or stainless steel please feel free to contact us at email address * forge HatI ma"plushotforging.com )note / please replace )at* sign in a+o1e email #ith 232 sign* THE FORGING PROCESS When metal is hot, it is in a soft and pliable condition allowing it to be easily formed under pressure without breaking. !his process is called forging. Fetal is strongest in the direction of its grain flow. Fachining cuts through the grain, thereby weakening the metal. Forging causes the grain to flow in the shape of the part. !herefore, forgings are stronger than machined parts. $lso, since the shape of the part is created by pressure, not cutting, much less metal is lost in the process. !his means that parts with comple" shapes can be formed and mass produced by forging more economically than by machining. Up

DROP FOR4I$4
% (rop forging is a mass production techni?ue which hammers the metal between two dies. Ealf of the die is attached to the hammer (upper section and half to the anvil (lower section . !he hot metal is placed in the lower half of the die and struck one on more time with the upper die. !his forces the metal to flow in all directions, filling the die cavity. G"cess metal s?uee,ed out between the die faces is called flash or flashing. $fter the forging is completed the flash is cut off in another press with a trimming die.

!P"'T FOR4I$4
Upset forging, also called hot heading, is a process by which the cross%sectional si,e of a bar is increased, either at an end or at some point along its length. 't is done on specially designed upsetting machines, using closed dies to control si,e

and shape. !ypically, dies have several stations, and the parts are formed progressively by moving the parts from one die station or cavity to another until the forging is complete. Eeads of bolts, valves, single and cluster gear blanks, artillery shells, and cylinders for radial engines are e"amples of parts made by upset forging. !his same process, when performed cold, is called cold heading . )old heading makes possible the economical mass production of fastenersP such as nails, screws, bolts, hinge pins, and rivets.