INDUSTRY DEFINED PROBLEM/PROJECT (IDP) STATEMENT FORM

STUDENT PARTICULARS
FIRSTNAME KARDANI
LAST NAME DIPAK
MOBILE NO. 1. 8238704272 2. 7359052622
EMAIL dipakkardani@gmail.com
ENROLLMENT NO: 120310119011
CLG NAME LUKHDHIRJI ENGINEERING COLLEGE,MORBI-2,363642
NEAR RAM MANDIR, KARDANI GATE, AT-BHIMORA
ADDRESS
TAL-UPLETA, DIST-RAJKOT, PIN-360490
BRANCH MECHANICAL ENGINEERING
SEMESTER 7TH YEAR 2015-16
TEAMNAME BZ-Icon
SIGNATURE

FIRSTNAME KARDANI
LAST NAME RAJ
MOBILE NO. 1. 9409258315 2.
EMAIL rajkardani918145@gmail.com
ENROLLMENT NO: 120310119014
CLG NAME LUKHDHIRAJI ENGINEERING COLLEGE, MORBI-2,363642
AT-BHIMORA, TAL-UPLETA, DIST-RAJKOT,
ADDRESS
PIN-360490
BRANCH MECHANICAL ENGINEERING
SEMESTER 7TH YEAR 2015-16
TEAMNAME BZ-Icon
SIGNATURE

FIRSTNAME MATARIYA
LAST NAME KRUNAL
MOBILE NO. 1. 7698612408 2.
EMAIL krunalmatariya@gmail.com
ENROLLMENT NO: 120310119020
CLG NAME LUKHDHIRJI ENGINEERING COLLEGE , MORBI-2, 363642
10, “GOMTI KUNJ” , VIVEKANAND SOCIETY-1.
ADDRESS
PALIYAD ROAD BOTAD, DIST-BOTAD, PIN-364710.
BRANCH MECHANICAL ENGINEERING
SEMESTER 7TH YEAR 2015-16
TEAMNAME BZ-Icon
SIGNATURE
FIRSTNAME TALAVIYA
LAST NAME VISHAL
MOBILE NO. 1. 9558497895 2.
EMAIL talaviyavishal30@gmail.com
ENROLLMENT NO: 120310119030
CLG NAME LUKHDHIRJI ENGINEERING COLLEGE, MORBI-2, 363642.
382-RACHNA SOCIETY, L.H.ROAD, SURAT-6
ADDRESS
PIN-395006
BRANCH MECHANICAL ENGINEERING
SEMESTER 7TH YEAR 2015-16
TEAMNAME BZ-Icon
SIGNATURE

INSTITUTE PARTICULARS
---------------INSTITUTE COORDINATOR---------------
NAME Mr. HARSHAD D. PATEL
CONTACT SAMAKANTHA NEAR MACHHU REVERBANK,
ADDRESS AT-MORBI, GUJRAT, PIN-363642.
MOBILE NO. 8866461140
EMAIL harshaddp@yahoo.co.in
SIGNATURE

INDUSTRY PARTICULARS
---------------INDUSTRY COORDINATOR---------------
NAME Mr ATULBHAI PRABHUDASBHAI BHADESHIYA
CONTACT “VRINDAVAN”, KOTHARIYA COLONY,
ADDRESS AT- RAJKOT
MOBILE NO. 09909200058
EMAIL atulgajjar876@gmail.com
---------------INDUSTRY---------------
NAME KISHAN AUTOPARTS LIMITED
G.I.D.C. LODHIKA PLOT NO. G-1324/25, KALWAD ROAD ,
POST: METODA
ADDRESS
DIST: RAJKOT-360021
GUJRAT INDIA.
CONTACT OFFICE 02827287761 MOBILE 9638201777
NO.
NAME OF INDUSTRIAL KISHAN AUTOPARTS LTD
ESTATE
COMPANY
LOGO
 INDUSTRY DEFINED PROBLEM STATEMENT FORM
TITLE OF PROBLEM/PROJECT

DIE LIFECYCLE IMPROOVEMENT IN HOT FORGING

PROCESS
(case study of connecting rod production)

PROBLEM SUMMARY
Company profile
Kishan forge pvt.ltd. (KFPL) came into existence from April 2004 with manufacturing set
up to produce world class forging of all kind. Kishan auto parts limited, the leading
manufacturing of connecting rod in India for both domestic as well as overseas market.
Kishan forge expanding facility of forging pressing, punching, shearing, load testing etc.
The company has a built up area of 11500 m2. Containing the administrative block,
forging shop, die shop, steel yard & staff quarters

About forging process(For this company)

Forging process is metal forming process in which piece metal is shaped to desired form
with help of plastic deformation of a simple starting from such as bar, billet, bloom or
ingot. The energy that causes deformation is applied by a hammer, press, up setters or ring
Roller either alone or a combination. The shape is imparted by tools that contact with
work piece and by careful control of Application of energy. In this company, produce a
wide a range of connecting rod and Internal combustion engine valve.

They use gravity drop hammer forging process for give initial shape of connecting rod.
The forging hammers are between 0.75 to 2 tonnes and capacity of forging products
ranges from 0.5 to 12 kg.

In this particular industry we observed during industrial sodhyatra, there are many process
for convert raw materials (billet) into finished product (connecting rod) are listed below:
1. Product design and process planning:
• Process planning
• Product design
• Simulation of prototype and generate the dies drawing.

2. Manufacturing of product (connecting rod and Dies)

• Making Impression die on VMC machine
• Cut the raw material from the ingot or billet
• Uniform heated the piece in furnace at desired temperature
• Attached the finished die on gravity drop hammer
• Making the forge product by successive forging step
 Impression dies forging
 Deep punching
 Edging
3. After forging(finishing steps)
• Cooling of forge product
• Shot blasting of finished product
• Removing the excess materials as per dimensional requirements by machining
process
• Quality checking of finished product

About The Problem:

In KFCL.PVT.LTD connecting rod manufactured by hot forging method. For that
Gravity drop hammer used for giving compressive force to hot material. Material is
flowing in die cavity. The raw material pieces are heated between 1100 to 1200
degreecelsius. The hot metal is directly contact with the die material so die material must
be preheated before the forging process start.

In all these process product quality mainly depend upon the impression of dies and
strength of dies, because if strength of die is not enough than the impression on the die
not withstand to high and successive impact forces. There were fatigue and thermal stress
induced in die material. After number of successive strokes die impression may be
opened, wear out and would not follow the dimensional accuracy and tolerances as per
our requirements.

As per that concern we decide to choose to reduce the die wear. Die wearing subjected to
increase the final cost of any forge material. Reason is that if die material is not properly
choose than it got fail after few impact strokes. To eliminate Die wear and Tear, all
necessary steps require to take is discus in our project.

We will try to find necessary solution of this problem with help of our knowledge, guides
guidelines and uses other references.
 DETAILED DESCRIPTION OF PROBLEM

As per above mentioned there are mainly three type of forging process.
1. Hot forging process
2. Cold forging process
3. Warm forging process

In hot forging process, the Billet is heated above its recrystallization temperature thus we
avoid strain hardening. Die wear in hot forging reduce due to elevated temperature of
finished product. So hot forging process is costly and also much care required for
production site.

In cold forging process, temperature of material is below the recrystallization temperature.

Cold forging is done at room temperature. Cold forging generally preferred when the metal
is already soft, like aluminium. This process is generally less expensive than hot forging and
less machining process required for producing finished product some time when aluminium
is cold forged to its desired shape it is heated at some temperature called tempering. Cold
forging employs dies that are sometimes similar to impression dies.

In warm forging process, the work piece is heated to a temperature significantly below the
typical hot forging temperature. Compared with cold forging, warm forging has advantages
of reduced tooling loads, reduced press loads, increased steel product ductility and
favourable as- forged properties that can eliminate heat treatment.

There are two types of hot forging process shown in figure.

Open die forging and closed die forging

Open die forging

In this type of forging process improve the plastic flow characteristics and reduce the force
required to work of the metal. It’s also known as a smith forging. In open die forging the
die do not enclose the workpiece, allowing it to flow except when contacted by the dies. It’s
generally flat in shape. Large and long part can be made by this process.

Close die forging

It utilizes a pair of matched dies with contoured impression in each dies that contain that act
to restrict the flow of metal within the die during the deformation of the work. The material
will fill the space within the die cavity as it is plastically compressed into the molds. Often
two or more progressive impression are used, sometime in conjunction with one or more
performing operation can done to form the desire shape.
 Fig 1 Example of connecting rod hot forging process

Problem shown in Hot Forging Die:

Here for particular hot and warm forging carried out by company directly faces the forging
defect if die design and their strength not proper.
The strength of die mainly depends upon the hardness of the die. Here DIN-2714 material
use for die which is alloy steel with chemical composition of carbon, manganese, silicon,
sulphur, phosphorous, chromium, nickel, molibledum, vanadium Etc. Its chemical equation
is 55CrNiVMo7. Hardness of this die material is near about 38 to 43 HRC.
Causes of Die failure:
• Over heating
• Over loading
• Abrasive wear

Over heating
If die temperature increase than wear resistance of the die decrease. Overheating create most
of the die wear in forging process. Overheating is likely to occur in areas of die impression
that projected into the cavity. Overheating mainly causes due to the long-time actuate of
forging process. This causes the rapid wear and tear.
In close die forging process hot billet material directly contact with steady die upper surface.
Hot and warm forging processes dies subject to serve cyclic thermal and mechanical fatigue
subsequently resulting in the die failure permissive through wear plastic deformation.
Hot forging die subjected to severe thermal and mechanical fatigue due to high pressure and
heat transfer between the dies and work piece.
Die cost can constitute up to 30% of the production cost of a part and also effect its
profitability directly to die manufacturing and cost indirectly repair press down time, scrap
and rework.

Overloading
Overloading mainly causes due to the grater force apply to the hot forging material which is
very high compared to die hardness. To avoid the overloading pre estimated stress
concentration and load carrying capacity decide and as per that particular die used for
forging process.

Abrasive wear
Abrasive is caused by the flow and spreading of hot metal in the cavity of forging die.
Abrasion is particularly severe if the design of forging is complex. Abrasion can eliminated
by proper die design, uses of good lubricant, careful selection of die composition, die
hardness and proper heating.

Factor Responsible for Die Wear:

• Incorrect choice of Die material
• Absent of die lubricant
• Improper die design
• Inhomogeneous billet temperature
• Less skilled operator
• Inaccurate grain flow direction
• Absent of surface treatment process
• Due to high friction coefficient between two die.
• Over heat temperature of die
• Improper force applied on die during forging
• Wrong selection of forging press
• Lack of Morden technology and product simulation
Figure shown below indicate finished die and defected Die.

Fig 2 Connecting rod dies without defect Fig 3 circular face plat die with wear

Fig 4 Connecting rod Die worn out edges and rough surface create due to cyclic operation
 EXPECTED OUTCOME
Possibility of increase dies life:
As per above discussion we mentioned that how can die wear and tear occurs, which
factor may be responsible for die wear. From that some factor we can’t totally
eliminated properly but proper case study and effective experiment give somehow
increase the die life. For that we deducted some points with help of internal, external
guide, some other reference books and practical examination. From that some point are
describe below.

The whole focus of our study based on die materials, die design, hardening, polishing,
forged billet temperature, lubrication during forging process for cooling the die. This
all the study carried out for particular gravity drop hammer forging process for close
die forging.
Steps for increase the die life suggest below:
 First of all we decide the die material selection as per the raw material and their
hardness.
 Care should be taken that hardness of the billet not greater than the die
material. This causes the die wear due to friction.
 Proper method and software use for die and connecting rod design. For that
skilled software operator required to generate 3D drawing for simulation and
2D drawing for worker understanding.
 After that precision machining operation required for die impression generate
as per drawing. Surface and internal cavity properly supper fined by grinding
and polishing.
 After mounting on the hammer, die actually preheated as per required
temperature properly and mount the die properly as their both the centre of axis
coincides on each other.
 For hot forging process billet are heated up to their recrystallization
temperature. Otherwise that excessive load required to forging the billet and
that tends to worn out the die.
 We also use proper lubrication for cooling the die materials. The main purpose
of applied lubricants is to achieve protection of die and tools, resistance to
stacking and release properties and reduce the friction. Examples of lubricants
are Graphite water based and oil based, non-graphite based, oil, boron nitride,
molybdenum disulphide, wax, grease and nickel Etc.