Professional Documents
Culture Documents
As Bhel
As Bhel
ON
GENERAL AWARENESS OF STEAM TURBINE
AT
HARIDWAR
SUBMITED TO
MR. A.K.SHRIVASTAV
MECHANICAL DEPARMENT
IIMT COLLEGE OF ENGG.
SUBMITED BY
SHUBHAM AGRAWAL
B.TECH (M.E-A)
th.
4 YEAR
ROLL-1121640100
Declaration
SHUBHAM AGRAWAL
B.Tech (M.E-4th.Yr.)
Roll No. -1121640100
PREFACE
Industrial training plays the most vital role in the career of an aspiring engineer. It
introduces the industrial world to the engineering student and links the theoretical
knowledge gained in the college classrooms to their practical application on the field.
It gives an idea to the student of what to expect after completing his engineering
3
course and prepares him better for his career up ahead. I consider myself highly
fortunate to be one of the few who get the opportunity to undergo their industrial
training at the BHART HEAVY ELECTRICALS LTD. Haridwar. The knowledge and
experience gained during the training period has been of incomparable value. The
training has helped me get an idea about the overwhelming scale of production at
the industrial level. It has also given me knowledge of the extraordinary level of
coordination and skill required to run an industry of such epic proportions. And in the
case of my field of study, mechanical engineering, it has given me the opportunity to
gain physical knowledge of the machinery used in the plant, which is invaluable for a
mechanical engineer. My days spent here have truly made me a better engineer by
further enhancing my knowledge by many folds and I am sure that this knowledge
will play a very important role in my career.
SHUBHAM AGRAWAL
B.Tech (M.E-4th.Yr.)
Roll No. -1121640100
Acknowledgement
The soul of any training program are its instructors. And in this case they are the highly
skilled and hardworking engineers, employees and workers of BHEL HWR who have played
an invaluable part in my industrial training. They have spent their most valuable time with
me to give as much of their knowledge to me as was possible during the timeframe provided.
To them goes my sincerest gratitude.
The list of those who helped me during my training period is very long but there are a few
individuals whose names need to mentioned because of whom this training program was
possible in the first place and to whom we owe most of the knowledge we gained in BHEL
HWR.
My thanks goes to Mr. RAJ SINGH, incharge HRDC haridwar because of whom this training
program has been possible. I thank to Mr. ALOK SHUKLA, Asst. G.M.OF Block 3 for his
cooperation and guidance which made our training period as comfortable as it could be
without compromising the opportunity to gain all the knowledge we could gain during the
training period.
My heartiest thanks goes to Mr. Sandeep kumar who has guided us through each and every
day that we have spent in BHEL HWR. If it wasnt for him, our training wouldnt have been
half as productive as it has actually been. He has also been the guiding force behind the
development of this report.
I also thank Mr. VIRENDRA KUMAR GUPTA, Mr. NANDKISHORE, for sharing their
highly valuable knowledge with us about the functioning of the respective units.
And in the end I would like thank the Almighty for sending this opportunity my way and
keeping me in good health during the training, my parents for their never ending support and
love and my group mates whose friendship made this experience more enjoyable and lively
than it could ever get.
SHUBHAM AGRAWAL
B.Tech (M.E-4th.Yr.)
Roll No. -1121640100
CONTENTS
S.NO
TOPIC
1.
Introduction
PAGE NO.
6-8
2.
Company Profile
9-11
3.
Major Products
12-13
4.
14-21
5.
Steam Turbine
22-33
6.
Another block
34
7.
34-38
8.
C.F.F.P PLANT
39-42
9.
CONCLUSION
43
10.
REFERENCE
44
(1.)INTRODUCTION
Bharat Heavy Electricals Ltd. (BHEL) is the largest engineering and
manufacturing enterprise of its kind in India and is one of the leading
international companies in the field of power equipment manufacture.In 1956
first step was taken by Indian government by establishing the first unit of Heavy
Electricals Engineering Manufacturing Limited at Bhopal . It progressed rapidly
and three more factories went into production in 1965.Heavy Electricals (India)
Limited formally merged with Bharat Heavy Electricals Limited (BHEL) in
1974. In 1969 BHEL supplied its first unit to Basin Bridge Thermal Power
Station in Tamil Nadu. Within a decade BHEL had commissioned the 100 th unit
at Santaldih,WB.The present scenario of BHEL consists of 11 manufacturing
divisions, 9 service centers, 4 power sector regional center, about 350 large
consumers(in India ) and many countries also. The companies inherent potential
coupled with its strong performance make this one of the MAHARATNAS,
which are supported by the government in their endeavor to become future
global players.
The Heavy Electrical Equipment Plant in Haridwar designs and manufactures
turbo generators, AC and DC motors, gas turbines and huge steams. The Central
Foundry Forge Plant in Haridwar deals with steel castings
The BHEL plants in Haridwar have earned the ISO - 9001 and 9002 certificates
for its high quality and maintenance. These two units have also earned the ISO 14001 certificates. Situate in Ranipur near Haridwar, the Bharat Heavy
Engineering Limited employs over 8,000 people and manufacturing of steel
forgings.
BHEL has a share of around 59% in India's total installed generating capacity
contributing 69% (approx.) to the total power generated from utility sets
(excluding non-conventional capacity) as of March 31, 2012. We have been
exporting our power and industry segment products and services for
approximately 40 years. We have exported our products and services to more
than 70 countries. We had cumulatively installed capacity of over 8,500 MW
outside of India in 21 countries, including Malaysia, Iraq, the UAE, Egypt and
New Zealand. Our physical exports range from turnkey projects to after sales
services.
BHEL work with a vision of becoming a world-class engineering enterprise,
committed to enhancing stakeholder value.
Our greatest strength is our highly skilled and committed workforce of over
49,000 employees. Every employee is given an equal opportunity to develop
himself and grow in his career. Continuous training and retraining, career
planning, a positive work culture and participative style of management - all
these have engendered development of a committed and motivated workforce
setting new benchmarks in terms of productivity, quality and responsiveness.
BHEL UNITS
UNIT
PERIOD
TYPE
1. Bhopal
Established 1956
Production started1960
2. Haridwar
Established 1963
HEEP
Production started1967
CFFP
Established 1974
Heavy
Electrical
Equipment
Plant,
Central Foundry Forge
Plant
Production started1976
3.Hyderabad
HPEP
4.Tiruchi
Established 1963
Production started1965
Established 1963
HPBP
Production started1965
SSTP
Production started1979
5.Jhansi TP
Production started1976
Heavy
Power
Equipment Plant
High Pressure Boiling
Plant
Transformer Plant
6.Banglore
EDN
Established 1963
EPD
Established 1972
ISG
Established 1977
8.Goindwal
Established 1983
9.Jagdishpur IP
Production started1984
10.Rudrapur
Production started1984
11.Gurgoan
Control
division
equipment
Electro
division
Porcelain
(2.)COMPANY PROFILE
BHEL HARDWAR
LOCATION
BHEL or the Bharat Heavy Engineering Limited is one of the largest
engineering and manufacturing organizations in the country and the BHEL,
Haridwar is their gift to Uttaranchal.
ADDRESS
Bharat Heavy Electrical LIMITED
Ranipur, Hardwar
PIN 249403
AREA
BHEL Hardwar consists of two manufacturing units, namely Heavy Electrical
Equipment Plant (HEEP) and Central Foundry Forge Plant (CFFP), having area
(a) HEEP: 845 sq km
(b) CFFP: 1.0 sq km
MANUFACTURING PLANTS
10
11
PRODUCTS
I. Electrical Machine
II. Fabrication
IV. Feeder
V. Fabrication
12
VI.FabricationStamping
and die manufacturing
Fabricated oil tanks, hollow guide blades, rings, stator frames, and
rotor spindle. All dies. Stamping for gen. and motors
LP heaters, ejectors, glands, steam and oil coolers, oil tank, bearing
covers.
Valves
Industry
Capacitors
Ceralin
Compressors
Desalination Plants
Diesel Generating Sets
Industrial Motors &
Alternators
Gas Turbines
Oil Field Equipment
Solar Photovoltaics
Power Semiconductor
Devices
Seamless Steel Tubes
Sootblowers
Steel Castings &
Forgings
Steam Generators
Steam Turbines
Turbogen
Transmission
Power
Transformers/Reactors
Instrument Transformers
Switchgears
Control & Protection
Equipments
Thyristorequipments
Insulators
Bushing
Capacitors
Transportation
Electric Rolling Stock
14
Non ConventionalEnergySource
Mini/Micro Hydro Sets
Solar Lanterns
Solar Photovoltaics
Solar Water Heating
Systems
Wind Electric Generators
R&D Products
Fuel Cells
Surface Coatings
Automated storage &Retrivals
Load Sensors
Transparent Conducting
Oxide
DETAILS OF BAY - 2:
DETAILS OF BAY - 2 Size:- 36x400 meters Rotor assembly section ,CNC
creep feed grinding machine, External broaching machine, CNC facing lathe,
Steam turbine test bed, Vertical boring machine,
DETAILS OF BAY 3 :
DETAILS OF BAY 3 Size :-24x402 meters CNC stub borer CNC milling
machine Universal milling machine CNC bed type milling machine CNC
surface broaching machine, steam turbine governing section
DETAILS OF BAY - 4:
DETAILS OF BAY - 4 Size:- 24x381 metres Turbine blade machining shop,
milling machines, jig and fixtures department, blade cutting section, Heat
treatment zone
MANUFACTURING FACILITIES:
(a) Hydraulic Lifting Platform: used for assembly and disassembly of G.T.
Rotor.
b) CNC Creep Feed Grinding M/c: grinds the hearth serration on rotor disc
faces.
c) External Broaching Machine: used to make groove on the outer dia of rotor
discs for the fitting of moving blades on the discs.
d) CNC Facing Lathe : used for facing rotor disc.
e) CNC Turning Lathe: used to turn Tie Rods of steam Turbine.
f) Wax Melting Equipment: used to mix and melt Wax to arrest the blade
movement during the blade tip machining of stator blade rings.
g) ROTOR ASSEMBLY SECTION : Equipped with Indicating Stand, Small
size Grinding, Milling, Drilling, machines, Press and other devices for fitting
Rotors and Discs.
h)TURBINE CASING ASSEMBLY SECTION : Machined casings are
assembled and hydraulically tested by Reciprocating Pumps at two times the
operating pressure.
I)TEST STATION : Equipped with condensers, Ejector, Oil Pumps, Oil
containers Steam Connections etc, required for testing.
j)OVER SPEED VACUUM BALANCING TUNNEL: Vibration and frequency
of rotor shaft is tested at very high speed of 4500rpm.
SPECIFICATIONS OF MACHINES AVAILABLE IN BLOCK-III:
16
:10000mm
:5000mm
Diameter of table
:8750mm
:3200mm
:200 T
:160mm
:1250mm
:100metric
:3200mm
:250mm
:16m
:100 T
Spindle bore
:96mm
CNC Lathe :
Manufacturer: Safop, Italy
17
to
:3500mm
Centre distance
:9000mm
Weight capacity
:120 T
Spindle power
:196KW
:250-2000mm
:200-1250mm
:200
CNC system
:SINUMERIK 840D
:5.3m
Turning length
:15m
Weight capacity
:160 T
:AP 80TM-6500
Table diameter
:6500mm
:8000mm
:660mm
18
:7000mm
Table Speed
:0.2-50 rpm
:200 T
:3.4-3000rpmat40KW
Spindle taper
:BT 50
CNC system
:SINUMERIK 840D
Step
:2300mm
:1800mm
:2000mm
:6000kg
:1800mm
:1.4-400rpm
:95.5KW
boring Machine :
Max boring diameter
Min boring diameter
Table
Max weight of job
Headstock travel
:2500mm
:625mm
:4000mmx4000mm
:100 T
:4000mm
:4000mm
:4250mm
:4200mm
:50 T
:200mm
:BT 50
:1600mm
19
Spindle length:2000mme
Headstock
Table :4000x35
CNC systemSIMENS
Job
:5000mm
: 850mm
: I.P. Outer
:250mm
:600mm
:2000mm
:1600mm
:2500mm
:2150mm
:15000mm
:1475mm
:140 T
:10.3m
:150mm
:12m
:1400mm
:1100mm
:4000kg
:20 T
:1250mm
:900mm
:6300mm
:25 T
:80mm
:55KW
:150mm
:2250x1250mm
20
:220mm
:8100 x 5000mm
:3mm
:6m
:6m
:1.8m
Manufacturer :Hoesch
Max load
Max length between centers
Swing over bed
Horizontal Borer : 2-198
Spindle diameter
Max vertical travel
Max transverse travel of column
Max longitudinal travel of column
Max longitudinal travel of spindle
Working surface
Creep Feed Grinding Machine :
Diameter of job
Job height
Table rpm
Table diameter
Swing diameter
CNC control
Broaching Machine : SIEMENS-3GG
Broaching capacity
Broaching stroke
Broaching slide width
Broaching specific cutting stroke
Broaching specific return stroke
Max diameter of disc
Max move of table
Helix angle/skew angle setting
Cone angle
CNC Lathe :
Manufacturer :InnseBerardi, Italy
Swing over carriage
Swing over bed
Capacity
Cost
CNC system
Over Speed Balancing of Turbines :
Main features :
22
:320 T
:18m
:3.2m
:220mm
:3m
:6m
:6m
:1.8m
:1800x500mm
:2m
:2.4m
:10rpm(max)
:2050mm
:2500mm
:32 T
:10.3m
:1500mm
:1.25m/min
:60m/min
:2300mm
:600mm
:+45/-45
:0-20
:1500mm
:2000mm
:30 T
:16 crore
:SINUMERIK 840D
Type of pedestials
Rotor weight
Rotor diameter
Rotor journal diameter
Bearing centre distance
Balancing speed
Min vibration limit
Max vacuum
:DH 90/DH 12
:Min 4 MT, Max 320 MT
:Max 6900mm
:Min 250mm,Max 950mm
:Min3000mm,Max 15700mm
:180-3600rpm
:1 micron
:1 torr
Tunnel Features :
Tunnel length
Tunnel diameter
Max thickness of tunnel
Steel plate thickness
Cost of balancing equipment(FE)
Total cost of balancing tunnel
Main Features of Drive :
Drive motors (2 no.)
Total drive pow:7 MW(2x3.5)
MG set of Drive :
Synchronous motors
DC Generator (2 no.)
:19000mm
:6900mm
:2500mm
:32mm
:444 lakhs
:770 lakhs
:950V DC, 500rpm,3.5 MW each
:11 KV,9MW,50Hz,500rpm
:950V,500rpm,3.8MW each
23
(5.)STEAM TURBINE:
24
several sets of blades, or buckets as they are more commonly referred to. One
set of stationary blades is connected to the casing and one set of rotating blades
is connected to the shaft. The sets intermesh with certain minimum clearances,
with the size and configuration of sets varying to efficiently exploit the
expansion of steam at each stage.
Turbine Efficiency
To maximize turbine efficiency, the steam is expanded, generating work, in a
number of stages. These stages are characterized by how the energy is extracted
from them and are known as impulse or reaction turbines. Most modern steam
turbines are a combination of the reaction and impulse design. Typically, higher
pressure sections are impulse type and lower pressure stages are reaction type.
Impulse Turbines
An impulse turbine has fixed nozzles that orient the steam flow into high speed
jets. These jets contain significant kinetic energy, which the rotor blades, shaped
like buckets, convert into shaft rotation as the steam jet changes direction. A
pressure drop occurs across only the stationary blades, with a net increase in
steam velocity across the stage.
Reaction Turbines
In the reaction turbine, the rotor blades themselves are arranged to form
convergent nozzles. This type of turbine makes use of the reaction force
produced as the steam accelerates through the nozzles formed by the rotor.
Steam is directed onto the rotor by the fixed vanes of the stator. It leaves the
stator as a jet that fills the entire circumference of the rotor. The steam then
changes direction and increases its speed relative to the speed of the blades. A
pressure drop occurs across both the stator and the rotor, with steam
accelerating through the stator and decelerating through the rotor, with no net
change in steam velocity across the stage but with a decrease in both pressure
and temperature, reflecting the work performed in the driving of the rotor.
MANUFACTURING PROCESSES :
27
250 MW
500 MW
600 MW
660 MW BASED ON NEW GERMAN TECHNOLOGY
H22
USA ASTM`
Alloy tool steel
Chemical composition
Element
Magnesium (Mg)
Manganese (Mn)
Iron (Fe)
Silicon (Si)
Titanium (Ti)
Others (Total)
Chromium (Cr)
Copper (Cu)
Zinc (Zn)
Other (Each)
Aluminium (Al)
%percentage
1.70 - 2.40
0.10 - 0.50
0.0 - 0.50
0.0 - 0.40
0.0 - 0.15
0.0 - 0.15
0.0 - 0.15
0.0 - 0.15
0.0 - 0.15
0.0 - 0.05
Balance
2.69 g/cm
625 C
25 x10-6 /K
134 W/m.K
70 GPa
29
Electrical Resistivity
0.044 x10-6 .m
Mechanical properties
Proof Stress
Tensile Strength
Hardness Brinell
WELDABILITY
Aluminium alloy H22 is a readily weldable alloy.
Weldability Gas: Very Good
Weldability Arc: Very Good
Weldability Resistance: Very Good
Brazability: Poor
FABRICATION
Workability Cold: Very Good
Machinability: Average
INSPECTION DEVICES:
INSPECTION DEVICES 3 D Coordinate Measuring Machines for taper and
rhomboid checking. Moment weighing Equipment.Real time Frequency
analyzer for checking frequency of free standing blades. Contour plotter for
plotting of blade profile with various magnification. Magna spray crack
detection equipment.
3d coordinate measuring machine in new blade shop:
Model refrence:
22129 LIETZ Germany
Plan no
3-068
Measuring range:
X axis
2200mm
Y axis
1200mm
Z axis
900 mm
Volumetric error: (max)
1.5 micron
Resolution:
0.05 micron
Max weight of job:
2250 kg
Accuracy:
1.5+L/350 micron
Application: dimensional and profile management of turbine
moving and guide blades
30
1 2 3
45 6
31
32
LP Rotor
LP Inner Casing Upper Half
LP Inner Casing Lower Half
LP Outer Casing Upper Half
LP Outer Casing Lower Half
IP Rotor
IP Inner Casing Upper Half
IP Inner Casing Lower Half
IP Outer Casing Upper Half
IP Outer Casing Lower Half
HP Rotor
HP Inner Casing Upper Half
HP Inner Casing Lower Half
33
Valve Seal
U-Ring
Piston Rod
Base Plate
Sealing Ring
Liner
Guide Ring
Valve Cover
Guide Blades :
Fixed Blades
Moving Blades
10)
Support
11)
Bearing
12)
Bearing Shell
13)
Angle Ring
14)
Sleeve
15)
Pin Taper (25x140)
16)
Journal Bearing Shell
17)
Casing
18)
Guide bush
19)
Piston (500MW)
20)
Valve Cone
21)
Yoke
22)
Mandrel
23)
Support Ring
24)
Thrust Ring
25)
Adjusting Ring
26)
Shaft Sealing Cover
Nomenclature of Blade:
1. Root
2. Ferate
3. Core Width
34
4. Shroud
5. Neck
6. Tang Hight
Types of blades:
1. Acoording to the profile
A. TX Blade
B. F Blade
C. 3DS Blade
D. Special Profile Blade
2. According to the Root
A. T Root
B. Double Root
C. Hook Root
D. Special Root
120 min
17.Fin intersection
18.Face Finishing
19.Final inspection
20. Blade out
(6.)ANOTHER BLOCK
(7.)BLOCK 2(heavy fabrication block)
The various processes and machinery are as follows:
A)HydraulicPress:Ahydraulic press is a hydraulic mechanism for applying
a large lifting or compressive force. It is the hydraulic equivalent of a
mechanical lever, and is also known as a Bramah press after the inventor,
Joseph Bramah. Hydraulic presses are the most commonly-used and efficient
form of modern press.The hydraulic press depends on Pascal's principle: the
pressure throughout closed system is constant. At one end of the system is a
piston with a small cross-sectional area driven by a lever to increase the
force. Small-diameter tubing leads to the other end of the system. A fluid,
such as oil, is displaced when either piston is pushed inward. The small
piston, for a given distance of movement, displaces a smaller amount of
volume than the large piston, which is proportional to the ratio of areas of
the heads of the pistons. Therefore, the small piston must be moved a large
distance to get the large piston to move significantly. The distance the large
piston will move is the distance that the small piston is moved divided by the
ratio of the areas of the heads of the pistons.
B)Oxy-Fuel Welding And Cutting: Oxy-fuel welding (commonly called
oxyacetylene welding or oxy welding or in the U.S. gas welding) and Oxy36
fuel cuttingare processes that use fuel gases and oxygen to either weld or cut
metals.
There are a few differences between the two. In Oxy-fuel welding, a welding
torch is used to weld metals. In Oxy-fuel cutting, a cutting torch is used to heat
up ferrous metal to kindling temperature (about 980C). A stream of pure
oxygen is trained on the hot metal which chemically combines with the iron
which then flows out of the cut, or kerf, as an iron-oxide slag
Torches that do not mix pure oxygen with the fuel inside the torch, but burn it
with atmospheric air, are not oxy-fuel torches and can be identified by their
single tank. (Oxy-fuel welding/cutting needs two tanks, fuel and oxygen.) Most
metals cannot be melted with such single-tank torches, so they can only be used
for soldering and brazing, not welding.
Apparatus used in Oxy-Fuel welding and cutting:
The apparatus used in gas welding consists basically of an oxygen source and a
fuel gas source (usually cylinders), two pressure regulators and two flexible
hoses (one of each for each cylinder), and a torch. This sort of torch can also be
used for soldering and brazing. The cylinders are often carried in a special
wheeled trolley.
There have been examples of oxyhydrogen cutting sets with small (scuba-sized)
gas cylinders worn on the user's back in a backpack harness, for rescue work
and similar.
There are also examples of pressurized liquid fuel cutting torches, usually using
gasoline. These are used for their increased portability.
C)Planers: A planer is a type of metalworking machine tool that is analogous to
a shaper, but larger, and with the entire workpiece moving beneath the cutter,
instead of the cutter moving above a stationary workpiece. The work table is
moved back and forth on the bed beneath the cutting head either by mechanical
means, such as a rack and pinion gear, or by a hydraulic cylinder.
Planers and shapers were used generally for two types of work: generating
accurate flat surfaces and cutting slots (such as keyways). Planers and shapers
37
are now obsolescent, because milling machines have eclipsed them as the
machine tools of choice for doing such work.
D)Plasma Cutting:Plasma cutting is a process that is used to cut steel and
other metals (or sometimes other materials) using a plasma torch. In this
process, an inert gas (in some units, compressed air) is blown at high speed out
of a nozzle; at the same time an electrical arc is formed through that gas from
the nozzle to the surface being cut, turning some of that gas to plasma. The
plasma is sufficiently hot to melt the metal being cut and moves sufficiently fast
to blow molten metal away from the cut.
Cutting Methods: Plasma cutters have also been used in CNC machinery.
Manufacturers build CNC cutting tables, some with the cutter built in to the
table. The idea behind CNC tables is to allow a computer to control the torch
head making clean sharp cuts. Modern CNC plasma equipment is capable of
multi-axis cutting of thick material, allowing opportunities for complex welding
seams on CNC welding equipment that is not possible otherwise.
E)Three roll bending machine: Roll benders use three rolls (typically) to bend
solids, extrusions and tube and pipe to various diameters by adjusting one or
two rolls. The pyramid style roll benders have one moving roll, usually the top
roll. Double pinch type roll benders have two adjustable rolls, usually the
bottom rolls, and a fixed top roll. Large arcs, circles and spirals are typical
applications for roll benders.
The roll bending machine in BHEL has following specifications:
Maximum working length:8000 mm.
Minimum diameter of forming:1300 mm.
Plate thickness:32 mm,
Upper rolled dia.:7550 mm.
Lower roll dia.:680 mm.
Speed of forming :5 m per minute.
Speed of lowering upper roll :60 mm per minute.
38
= 4m
41
42
43
FORGING
Forging is a manufacturing process involving the shaping of metal using
localized compressive forces.
Forging is often classified according to the temperature at which it is performed:
1. Cold Forging
2. Hot Forging
All of the 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
deemed hot forging.
if the temperature is below the material's recrystallization temperature but above
30% of the recrystallization temperature (on an absolute scale) it is deemed
warm forging;
if below 30% of the recrystallization temperature (usually room temperature)
then it is deemed cold forging.
The main advantage of hot forging is that as the metal is deformed work
hardening effects are negated by the recrystallization process. Cold forging
typically results in work hardening of the piece.
Forged parts can range in weight from less than a kilogram to 580 metric tons.
Advantages and disadvantages
Forging can produce a piece that is stronger than an equivalent cast or machined
part. As the metal is shaped during the forging process, its internal grain
deforms to follow the general shape of the part. As a result, the grain is
continuous throughout the part, giving rise to a piece with improved strength
characteristics.
Some metals may be forged cold, but iron and steel are almost always hot
forged. Hot forging prevents the work hardening that would result from cold
forging, which would increase the difficulty of performing secondary machining
operations on the piece. Also, while work hardening may be desirable in some
circumstances, other methods of hardening the piece, such as heat treating, are
generally more economical and more controllable. Alloys that are amenable to
precipitation hardening, such as most aluminium alloys and titanium, can be hot
forged, followed by hardening.
Production forging involves significant capital expenditure for machinery,
tooling, facilities and personnel. In the case of hot forging, a high-temperature
furnace (sometimes referred to as the forge) is required to heat ingots or billets.
Owing to the massiveness of large forging hammers and presses and the parts
they can produce, as well as the dangers inherent in working with hot metal, a
special building is frequently required to house the operation. In the case of
drop forging operations, provisions must be made to absorb the shock and
44
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