MAHARASHTRA STATE BOARD OF TECHNICAL EDUCATION,

MUMBAI

A PROJECT REPORT ON

INDUSTRIAL TRAINING
AT
BHARAT FORGE LTD.

SUBMITTED TOWARDS THE

PARTIAL FULFILLMENT OF THE REQUIREMENTS OF

DIPLOMA IN MECHANICAL ENGINEERING

BY

NAME: JANGALE ANSHUL ANIL ENROLLMENT NO.: 1901300408

UNDER THE GUIDANCE OF

MENTOR: Mr.R.M.MANE

DEPARTMENT OF MECHANICAL ENGINEERING

GOVERNMENT POLYTECHNIC, AHMEDNAGAR

BURUDGAON ROAD, AHMEDNAGAR, 414001

 Maharashtra State Board of Technical Education,
Mumbai

Certificate of Completion
Of industrial training
(By respective head of the Institute & Head of Department)

This is to certify that Mr. JANGALE ANSHUL ANIL With

Enrollment No. 1901300408 has successfully completed Industrial
training of Diploma in Mechanical Engineering from Government
Polytechnic, Ahmednagar.

Signature of Seal of the Institute Signature of

Head of department Student

 ABSTRACT

Industrial training course is introduced to all programs

with an objective to develop the traits of industry culture
among the students before they enter into world of
industry. By exposing and interacting with the real life
industrial setting, student will appreciate and understand
the actual working of an industry, best practices adopted in
the industry. The industrial skills like, soft skills, life skills
and hands-on will be inculcated among the student. The
short association with industry will be instrumental in
orienting the students in transforming them into industry
ready output after completion of diploma program.

EXPECTED SKILLS FROM INDUSTRIAL

TRAINING :
1. Soft Skills i.e. Communication, Presentation etc.
2. Life Skills i.e. Time management, Safety, Innovation,
Entrepreneurship, Team building etc.
3. Hands-on i.e. Design, Implementation and Quality Assurance
aspects etc.
4. Industry specific tools i.e. Value Engineering, 6 Sigma and Lean.
 ACKNOWLEDGEMENT

I would like to thank my industrial training mentor

Mr.R.M.Mane sir to give me guidance during my Industrial
Training Program. I would also thanks for all the support
which have been given me during this session.
I would also thank our head of the department
Ms.P.P.Kulkarni mam for support and suggestions which
were very helpful for us during the training program.
Lastly I would like to thank our Principal Prof.M.S.Satarkar
sir for providing us such a great opportunity of industrial
training program.

Jangale Anshul
(Diploma in Mechanical Engg.)
 INDEX

Sr.No. TOPIC

1. INTRODUCTION TO INDUSTRY

2. PRODUCTS

3. MAJOR EQUIPMENT USED

4. MANUFACTURING PROCESSES

5. TESTING AND QUALITY ASSURANCE

6. MATERIAL HANDLING EQUIPMENTS

7. SAFETY PROCEDURES FOLLOWED

8. CHALLENGES EXPERIENCED DURING TRAINING

 INTRODUCTION TO INDUSTRY

Bharat Forge Limited (BFL), the Pune based Indian

multinational is a technology driven global leader in metal
forming, having a transcontinental presence across ten
manufacturing locations, serving several sectors including
automotive, power, oil and gas, construction & mining,
locomotive, marine and aerospace. The company was
founded by Dr. Nilkanthrao A. Kalyani, in 1961. The current
chairman of the company is his son, Baba Kalyani. Amit
Kalyani, Baba Kalyani’s son, is the Executive Director of the
company. Part of Kalyani Group - a USD 3 billion
conglomerate with 10,000 global work force. BFL today has
the largest repository of metallurgical knowledge in the
region and offers full service supply capability to its
geographically dispersed marquee customers from concept
to product design, engineering, manufacturing, testing and
validation. The world's largest forging company with
manufacturing facilities spread across India,
Germany,Sweden, France and North America, Bharat Forge
manufactures a wide range of high performance, critical &
safety components for the automotive & non-automotive
sector.
It is India's largest manufacturer and exporter of automotive
components and leading chassis component manufacturer
in the world. BFL's customer base includes virtually every
global automotive backed by several decades of experience
in component manufacturing & metallurgy, the company
has embarked on an ambitious and exciting journey to
redefine its already existing presence across several critical
business verticals such as oil & gas, power, locomotive &
marine, defence & aerospace, metals & mining, construction
and general engineering.
Bharat Forge is using its strong platform of metallurgical
knowledge, design & engineering capability and
manufacturing prowess, to create a strong position for itself
in these sectors.‘Expanding into new horizons’ has given
Bharat Forge a completely new growth perspective. It has
transformed the company from an auto component
supplier to an engineering company with diverse
complementary businesses in new high growth sectors.
Spirit of Innovation is the core of the organization’s DNA
and plays a paramount role in delivering value to Bharat
Forge customers through extensive focus on technology
and value addition. Bharat Forge is passionate about
continuously exploring new ideas and delivering solutions
for change. Innovation has been the driving force behind
our company and is applied across every aspect of our
business. As Bharat Forge expand their expertise across
sectors, vision is clear.
Bharat Forge’s products include front axle beams, steering
knuckles, connecting rods and crankshafts. The new
strategy is to augment a strong global footprint in
Lightweight materials. As part of its risk mitigation efforts,
Bharat Forge diversified into a variety of industrial sectors
including oil & gas, infrastructure, and marine. Some of
BFL’s largest customers include Daimler Group, VW Group,
Meritor and Dana etc. The company also has an extensive
collaboration with major truck manufacturers.

History
Bharat Forge Ltd is one of the most innovative and exciting
companies to emerge in the history of the forging industry.
The Indian Automotive Industry in the 50’s was more like
the story of imported kits. Ancillaries were nominal and
infrastructure was scarce and inadequate. It was then, that
Bharat Forge came into existence in 1961 to meet the
forging needs of the Indian Automotive Industry.
The 70’s witnessed a spurt in the Indian forging industry
with more and more units coming up. For Bharat Forge, it
was a period of consolidation and growth. With the largest
integrated facilities in Asia and an unbeatable track record,
Bharat Forge emerged as the undisputed leader - the first
name in the forgings industry in India.

With an emphasis on diversification, the 80’s saw Bharat

Forge grow from a primarily automotive ancillary to an
engineering enterprise focusing on technological
supremacy, resilience and total customer-orientation.

Today, the art of forging metal is a tradition at Bharat

Forge, and all of our products are built with the expertise
necessary to accommodate various industries. Each
customer specification is carefully transformed into a cost-
efficient reality. Every part Bharat Forge create a
representation of our overall dedication to craftsmanship.

An outstanding reputation for customer service coupled

with the Management commitment to quality has made
Bharat Forge the preferred domestic and global supplier for
major OEM’s. Under the intense and caring supervision of
the Chairman & Managing Director, Mr. Babasaheb N.
Kalyani, the company continues to expand and its markets
continue to grow, while the goal remains the same : to
deliver competitive, quality products and services - time
after time.
Vision and Mission
▪ To be committed to listening and responding to the
needs of our customers, associates and business
partners and honoring their individual value.
▪ To be committed to an entrepreneurial spirit that fuels
the growth of our companies and increases
shareholder value.
▪ In expanding global markets, technology based
innovation is the most important driver of growth.
▪ To build world class manufacturing plants and
reaching global scale capacities in our line of
businesses.
▪ To build partnerships with major global OEMs and Tier
I companies around the world, offering full service
supply capability.
▪ Spirit of innovation is the core of the organization’s
DNA and plays a paramount role in delivering value to
customers through extensive focus on technology &
value addition.
National Presence
1. Location: Pune, India
Sector: Commercial Vehicles, Passenger Vehicles,
Transportation (Rail, Marine, Aerospace), Power
(Wind, Thermal, Hydro), Energy (Oil & Gas),
Construction & Mining.

2. Location: Baramati, India

Sector: Commercial Vehicles, Passenger Vehicles,
Railways, Aerospace, Marine & Power.
 3. Location: Satara, India
Sector: Industrial sectors – Wind Energy, Oil &
Gas & Power.

Global Presence
1. Location: Germany
Sector: Commercial Vehicles, Passenger Vehicles
Railroad Components, Construction machinery.
2. Location: Germany (Second plant)
Sector: Premium passenger vehicles

3. Location: Sweden
Sector: Commercial Vehicles.

4. Location: France
Sector: Industrial (Oil & Gas).
5. Location: North America
Sector: Commercial Vehicles, Passenger Vehicles,
Industrial sectors.
 PRODUCTS
Bharat Forge manufactures an extensive array of critical
and safety components for several sectors including
Automobiles (across Commercial & Passenger Vehicle), Oil
& Gas, Aerospace, Locomotives, Marine, Energy (across
renewable and non-renewable sources), Construction,
Mining and General Engineering.
Bharat Forge has achieved its success through
transformation as a leading critical component
manufacturer and it continues to remain the only way
forward. Our transformational DNA is helping us leverage
opportunities across the world. Bharat Forge continues to
leverage its expertise built on 4M’s (Metallurgy, metal
forming, manufacturing and machining) and R&D
capabilities, to provide agile and adaptive solutions to its
customers and establish itself as one of the best critical and
safety components manufacturer both in India and globally.
Developing our own technology, constantly improving our
technical processes, adopting the latest manufacturing
practices as a critical component manufacturer and
continuously training our workforce to create a talent
factory has been the keystone in building a strong
foundation. Our focus on developing new processes,
expanding the product portfolio, and leveraging our
innovation capabilities, is opening up new growth avenues.
Bharat Forge is reinventing ourselves as a global
engineering company with a deeper presence across varied
sectors in order to make us known as one of the best
critical and safety components manufacturer.

Automotive
Bharat Forge is the largest
exporter of Auto
Components from India and
one of the leading chassis
components manufacturer
in the world.
Bharat Forge Customer base
includes virtually every
global automotive OEM and
Tier I supplier. As an auto
forged components
manufacturer, Bharat Forge has always been able to
support our automotive customers by helping them meet
stringent environmental norms, and improving fuel
economy with our products. Today, Bharat Forge is
amongst the few global auto component manufacturers in
India, with capability to offer:
▪ Front line design & engineering
▪ Dual shore manufacturing capability
▪ Full service supply capability
Automotive products of Bharat Forge
Engine parts:
▪ Crankshafts.

▪ Connecting Rod

▪ Emission
 ▪ Fuel injector system common rail

Chassis
▪ Front axle beam

▪ Steering knuckles

▪ Control arm, knuckle, fork

 ▪ Reinforcement bracket

Transmission and driveline

▪ Transmission component

▪ Driveline component
Aerospace
The Aerospace business unit is
a leading supplier of various
components - airframe,
structural and engine parts for
the aviation sector. Bharat
Forge is known to be one of the
best aircraft compressor
manufacturer in India.
Bharat forge Manufactures airframes, structural and engine
parts for airplanes of various makes and models. As an
aircraft turbine and compressor manufacturer India, the
Company manufactures high end shafts, LPC Discs and HP
Discs for airlines. Aero engine components – Blisk Blades,
OGV Blades and Fan Blades manufactured by us are made
in keeping with the latest technology and design trends
while maintaining high quality standards. This has made us
a renowned aircraft fan blade manufacturer in the aviation
sector in India.
Bharat Forge aerospace facilities include:
5 axis milling machine, 6 axis polishing machine, Band Saw
Cutting, Billets Coating, Chamfering Machine, Chemical
Etching Line, CMM, Fluorescent Penetrant Inspection Line,
Hexagon scanner, Magnetic Particle Inspection Line (MPL),
Raw Material Storage, Billet preparation, Chamfering
station, Glassing station, Shot blasting, Chemical etching,
FPI line, CMM station

Bharat Forge aerospace products:

▪ Fan blade

▪ Compressor and turbine

• Aero structure
 ▪ Landing gear component

Oil and Gas

Bharat Forge has developed
a reputation for supplying
high value and high
technology oil and gas
forgings supplier in the
Indian and global markets
with applications across
surface, sub-sea, deep-sea
and shale. The differentiated technology expertise
displayed by the Company as a gas and oil forgings supplier
has helped win prestigious orders from our customers who
are top global high technology oil forgings supplier and gas
players.
With vast repository of metallurgical knowledge as a high
technology gas forgings supplier and in-house innovation
capabilities, Bharat Forge is well-set to play a value
addition role in manufacturing critical equipment and high
technology oil and gas forgings products needed in the oil
and gas sector.
As a gas forgings supplier, Bharat Forge has a wide spread
supply chain capable of handling multiple primary and
secondary processes including Open Die Press, Ring
Rolling, Close Die Hammer, Finish Machining and Cladding
which helps us to deliver turnkey services. Bharat Forge as
a high technology oil forgings supplier, has extended its
capabilities to component machining and mechanical
assemblies to meet the demands of increasing customer
base.

Oil & Gas Products from Bharat Forge:

▪ Subsea
▪ Surface

▪ Drilling
Power
Bharat Forge supplies critical
components for renewable and
non-renewable energy sources.
Bharat Forge is constantly
expanding our product portfolio
and customer base with the shift
from sub to super-critical power
plants coupled with the growth
in renewable energy sector.
Bharat Forge cater to the Power
Generation sector across
geographies and supply critical
components that are used for power generation from
sources such as thermal, hydro and wind energy.

Bharat Forge Power Products:

Hydro
▪ Rotor
 ▪ Other components

Wind
▪ Shafts
 ▪ Gear box

Thermal
▪ Rotor shaft
Construction and Mining
The equipment used in
Construction & Mining and
General Engineering sector
have extreme applications
and hence require equally
durable products. Bharat
Forge has established itself
as a quality construction
component manufacturer by
making high end
construction products like tracklink, front spindles and
engines.
With its metallurgical expertise, technological know-how
and manufacturing prowess, Bharat Forge has over the
years been supplying critical components for Construction
and Mining industry establishing itself as one of the best
mining component manufacturer and maker of
construction components. The Company also manufactures
products for a range of heavy engineering applications.
As a renowned mining component manufacturer and maker
of construction components, Bharat Forge has a wide
variety of products to offer ranging from Tracklinks and
Front Spindles to Engines.
As a construction component manufacturer, Bharat Forge
strongly believe in providing total customer satisfaction
through excellence in our products and process
development.

Bharat Forge Construction and Mining products:

▪ Tracklink

▪ Front Spindle
 ▪ Engine

Marine
Bharat Forge supply various
products to the global ship
builders, including key
products like crankshafts,
connecting rods and propeller
shafts. Bharat Forge is one of
the most reliable connecting
rod manufacturers in India and also rank amongst the best
crankshaft manufacturers in India.
The crankshaft is one of the most important parts of a ships
engine, which is why crankshaft manufacturers take great
care in manufacturing them. This is why Bharat Forge use
the latest technology to manufacture world class
crankshafts for engines to move ships smoothly across the
deepest oceans. High quality, durable conrods and piston
rods manufactured by us have helped us build a reputation
of being the best amongst connecting rod manufacturers in
India and globally. Other marine products manufactured by
us includes products for the shafts – propeller, marine
motor and stem tube and products for the rudder – stock,
trunk and pintel.

Bharat forge Marine Products:

▪ Shafts

▪ Engine
 ▪ Rudder

Railway
Bharat Forge leverages its
advanced manufacturing
technology to supply critical
engine components to all
major railway networks
globally.
As a railway engine parts
manufacturer, Bharat Forge
make a variety of railway
components that are much in demand in the railway
industry. These include Engine components such as
crankshafts, connecting rods, pistons, deck ends, retainer
cylinder heads; Turbochargers like Machined Compressor
Impeller, Turbine Wheel Impeller Balance Assembly and
Turbine Disc Bucket Assembly; various bogie components
and Power Electronics.
Bharat Forge Railway Products:
▪ Engine Components

▪ Turbocharger
▪ Bogie Component

▪ Power Electronics
Bharat Forge Clients/Customers
• BMW
• Ford
• DaimlerChrysler
• Volvo
• GM
• Caterpillar
• Toyota
• Volkswagen
• ArvinMeritor
• Honda
• Audi
• Renault
• Man
• Cummins
• New Holland
• Daf
• Fawde
• Perkins
• Tata
• Mercedes-benz
• Mahindra
• Maruti Suzuki
• Larson Turbo
• Ashok Leyland
• Escorts
• Bajaj
• BHEL
 Major Equipment Used
▪ Anvil:
Anvils are types of forging tools that
serve as a workbench for blacksmiths.
It is a large slab of metal usually made
of steel. It is used to perform different
operations like, flatting metal surfaces
and obtaining shapes with the used of
hammer. Some anvil contains hardy holes and punches
holes. The hardy hole serves as square shank for hardy and
the punch hole provides clearance for punching hole in the
metal.

▪ Chisel:
chisel is used for cutting and
chipping out metal. It is made of
high petroleum steel with an
octagonal cross-section with a
tapered cutting edge on one end.
Chisel used in forging is of two
types, Hot and cold chisel. Hot
chisel is used for hot forging and cold chisel is used for cold
forging.

▪ Fuller:
Fuller helps to create groove or indentions
in the forging process. It is also used to
stretch the metal. Fuller works in pears,
by placing one beneath the metal, and the
other on top. This allows the indentation
of both sides of the metal to occur
simultaneously.

▪ Hammer:

Hammers are types of forging tools used in several ways,

base on the type of forging needed to be performed, such
as, hot forging, cold forging, closed die forging, upset
forging, press forging etc. Hammer serves as a forging tool
used in achieving shapes on work pieces. It is used as a
striking tool and can be classified as, drop hammer and
power hammer.
 ▪ Tong:

These types of forging tools are used for holding and

turning hot metals. Tongs are available in different types
and sizes. They are classified based on the grip of the tongs.

▪ Punch and drift:

These types of forging tools
are made of high carbon steel
which helps in making hot
hole on hot metal pieces. This
forging tool is available in
different sizes and has a
common shape. Drift is a
large size of punch used in
enlarging holes.

▪ Flatter:
this forging tool is used to flatten the surface
of the work piece. It consists of a plane face
joined with a straight shank. Flatters
materials are high carbon steel.
 ▪ Swage:
Swage is a forging tool type that
gives various shapes to the work
piece. It is also made of high-carbon
steel.

▪ Swage block:
this forging equipment is made of cast
iron or cast steel rectangular block, having
several holes in it. The holes are made of
different sizes and shapes.

▪ Set hammer:
Set hammer is a forging tool used for making surface plane,
forming and making corners. This
forging tool has similar shapes with
flatter. It is made of tool steel. The
work piece must be placed on an
anvil before a set hammer can be
used.

▪ Clamping vice:
this forging equipment is used in
holding workpieces in the smithy
show. It consists of two jaws, a spring,
and a flat bottom. The work pieces are
clamped between two jaws and tighten
to hold it strongly.
 ▪ Bick iron:
This forging equipment is made of tool steel
and it is hardened. It has a tapered tail at one
side and the other portion is similar to the
horn of an anvil. This forging equipment can
also work on an anvil due to its taper shank.

▪ Press:
This forging equipment uses excessive
pressure to fold metal into the desired
shape. This forging equipment can forge the
entire product at once. Presses are available
in two types, mechanical and hydraulic
press forging.

▪ Forging dies:
This forging equipment is required to
properly mold metal. It serves as molds
into which malleable metals are pressed.
The dies are important in all forging
projects; it is used for large production and
complex job. Dies are available in two
types: open die and close die.
Open die: open die does not completely
encase the metal, providing free flow
everywhere except the metal meets the die.
Closed die: closed die completely encased the metal when
hammered or pressed against the metal.

▪ Furnace or hearth:
These forging tools are used by blacksmiths for
heating metal pieces. They usually consist of
four legs, cast iron or steel body, iron bottom, a
chimney, and a blower.

Forging at Bharat Forge

Bharat Forge enables power production through renewable
resources.
Bharat Forge is one of the few green forging companies in
the world, with majority of its power produced by
renewable resources.
Over the years Bharat Forge has created world-class
capacities and capabilities. Our forging facilities consists of
fully automated forgings press lines ranging from 1600T to
16000T. All the forging press lines are highly flexible, which
gives the company the inherent advantage to
simultaneously meet different customer demands and
optimize production. This allows Bharat Forge to meet the
growing demands of its customers continuously.
Closed Die Forging

Open Die Forging

Hammer & Ring Rolling
 Manufacturing Processes
Different type of forging processes and their working
followed in Bharat Forge :
Drop Forging Process
Drop forging gets its name from the process of dropping a
hammer onto the metal to mold it into the shape of the die.
The die is the surface that comes into contact with the
metal. There are two types of drop forging: open-die and
closed-die forging. Dies are typically flat in shape with some
having distinctively shaped surfaces for specialized
operations.
Open Die Forging Process
When flat dies that have no precut profiles engage in
forging, the forge process is called open die forging (or
smith forging). The open design allows the metal to flow
everywhere except where it touches the die. To achieve
maximum results, correct movement of the workpiece,
which should be over 200,000 lbs. in weight and 80 feet
long, is essential. It is useful for short-run art smithing or
for shaping ingots prior to secondary shaping measures.
Open die forging creates pieces with better fatigue
resistance and strength and reduces the chance of error or
holes. It can also be used for a finer grain size than other
processes.
Closed Die Forging Process
Closed die forging, sometimes called impression die forging,
employs the use of molds. These molds are attached to an
anvil while a hammer forces molten metal to flow into the
cavities of the die. Multiple strikes and/or die cavities are
often used when forging complex geometries. High initial
tooling costs make closed die forging expensive for short-
run operations, but the forging process becomes cost-
effective as parts produced increases. Closed die forging
also provides exceptional strength over alternative
methods. Common applications of closed die forging
include the production of automobile components and
hardware tools.
Press Forging Process
In press forging, the main forming factor is compression.
The metal sits on a stationary die while a compression die
applies continuous pressure, achieving the desired shape.
The metal’s contact time with the dies is considerably
longer than other types of forging, but the forging process
benefits from being able to simultaneously deform the
entire product, as opposed to a localized section. Another
benefit of press forging is the ability of the manufacturer to
monitor and control the specific compression rate.
Applications of press forging are numerous, as there are
relatively no limits to the size of product that can be
created. Press forging can be hot or cold forged.
Roll Forging Process
Roll forging is the process of increasing rods or wires in
length. The manufacturer places heated metal bars between
two cylindrical rolls with grooves, which rotate and apply
progressive pressure to shape the metal. The precisely
shaped geometry of these grooves forges the metal part to
the desired shape. The benefits of this forging method
include the elimination of flashing and a favorable grain
structure. While roll forging uses rolls to produce parts and
components, it is still considered a metal forging process
and not a rolling process. Roll forging is frequently used to
make parts for the automotive industry. It is also used to
forge things like knives and hand tools.
Upset Forging Process
Upset forging is a forging process that increases the
diameter of the metal through compression. Crank presses,
a particular high-speed machine, are used in upset forging
processes. Crank presses are characteristically set on a
horizontal plane to improve efficiency and the quick metal
exchange from one station to the next. Vertical crank
presses or hydraulic presses are also used. The advantages
of this process are that it enables a high production rate of
up to 4500 parts per hour and full automation is possible. It
also produces little to no waste.
Isothermal Forging Process
Isothermal forging is a forging process where the materials
and the die are heated to the same temperature. The name
comes from “iso” which means “equal.” This forging method
is commonly used for forging aluminium, which has a lower
forging temperature than other metals such as steel.
Forging temperatures for aluminum are around 430 °C,
while steels and super alloys can be 930 to 1,260 °C. The
benefits are the near net shapes lead to lower machining
requirements and, therefore, lower scrap rates, and the
metal part is highly reproducible. Another advantage is that
smaller machines can be used to make the forging due to
the lower heat loss. A few disadvantages are the higher die
material costs to handle temperatures and pressures and
the required uniform heating systems. It also has a low
production rate.
 Testing and Quality Assurance

Bharat Forge has set up a full-fledged product testing and

validation facility, one of the largest of its kind in the
Industry.
Forge has a world-class state-of-the-art advanced fatigue
testing facility approved by global OEM’s for validation of
various components to ensure higher and consistent level
of quality.
Testing facility includes resonant testing method for
bending & torsion fatigue test of crankshafts ranging from
smaller capacity passenger car to large capacity marine &
rail crankshafts. Resonant fatigue test is carried out using
Electrodynamic shaker systems of capacity ranging from
150 Kgf to 2700 Kgf at fully reversed loading condition.
The other automotive components like Front Axle beam,
Rear Axle beam, Stub Axle, Connecting rod fatigue testing is
carried out using Servo hydraulics actuator rigs of capacity
250 KN & 630 KN. Fatigue testing capabilities include
advanced facilities of strain measurement, Crack detection
techniques and complete Metallurgical analysis of fatigue
failure specimens. This enables Bharat Forge to provide
complete end-to-end solutions to its customers from
product conceptualization to designing and finally
manufacturing, validation & testing.
Testing methods done in Bharat Forge are :

▪ Chemical Testing
Forging test methods are available to verify the chemistry
of material to be certain it’s what it should be and within
specification.
1. Atomic Emission Spectroscopy (AES)
2. Combustion Analysis
3. Inert Gas Fusion
4. ICP Mass Spectrometry (ICP-MS)

▪ Mechanical Testing
Testing is offered for the principal mechanical properties of
interest to designers in the forging industry,
including strength, ductility and hardness.

1. Hardness Testing
2. Tensile Testing
3. Charpy Impact
4. Bend
5. Fracture Toughness
6. Fatigue Crack Growth
7. Low and High-cycle Fatigue
 ▪ Nondestructive Testing
Both surface and internal flaws can be detected with our
NDT test methods.
1. Ultrasonic
2. Radiographic
3. Magnetic Particle
4. Liquid Penetrant

▪ Destructive Testing
Destructive testing involves applying controlled and
measured forces to a piece of material until it fails. (This
type of testing is carried out on a test note, an extra
forging, or a section of a forged workpiece that was
removed from the final product undergoes to testing.)
Bharat Forge destructive testing include :
1. Stress Rupture Testing:
2. Tensile Testing:
3. Grain Size Testing
4. Charpy Impact Testing
5. Micro Examination
6. Macro Examination

▪ Metallurgical Testing
Physical characteristics of forged materials can be
evaluated and defects or flaws identified with metallurgical
examination techniques.
 1. Microstructure
2. Grain Size
3. Micro-Cleanliness
4. Macrostructure

Laboratory facilities for testing

Bharat Forge has a world class state of- the art advanced
laboratory facilities for validation of various components to
ensure higher and consistent level of quality.
 Material Handling Equipment
There are 4 Categories of Material Handling
Equipment used in Bharat Forge
1. Storage and Handling Equipment
This equipment category is self-explanatory. Storage and
handling equipment is used to hold materials while they
aren’t being used. The material commonly stored on this
type of equipment is usually waiting to enter the
production cycle or waiting to be transported. Here are
some of the most common pieces of storage and handling
equipment:
• Drawers, bins, and shelves: These are the most basic
storage items commonly used to store smaller
materials in an organized manner.
• Racks: Racks help companies store materials in
accessible locations, and they save floor space.
• Stacking Frames: These are interlocking units that
enable materials to get stacked without being crushed.

2. Bulk Handling Equipment

Bulk handling equipment refers to equipment that
transports, stores, and controls bulk materials. This type of
equipment is generally used to move and store materials in
a loose form. Common examples of this type of equipment
include:
 • Stackers: Like forklifts, stackers help lift and stack
heavy loads on the dock or in the warehouse.
• Reclaimers: These are large machines used to recover
bulk materials from a stockpile.
• Bucket elevators: These elevators (also known as grain
legs) assist with hauling bulk materials vertically.
• Silos: Silos are towers that hold materials. Materials
that are typically stored in silos include grain,
woodchips, coal, and sawdust.

3. Industrial Trucks
Industrial trucks are essential for warehouses and
distribution centers. These powered trucks, such as
forklifts, move large quantities of materials around the
manufacturing floor. They are also utilized to load or
unload heavy objects onto delivery trucks efficiently.
• Hand trucks: Hand trucks (also called dollies) are a
simple piece of equipment designed to give operators
the leverage they need to move heavy materials to new
locations.
• Sideloaders: Sideloaders are built to fit in narrow
aisles. They pick up items from different directions,
making them ideal when a warehouse has aisles close
together.
• Pallet trucks: Otherwise known as forklifts, pallet
trucks are machines operators use to lift heavy pallets.
 The forks slip under the pallet, lift it, and secure it as
the operator takes it to a new location.

4. Automated Systems
Automated or engineered systems refer to automated
material handling equipment made to help transport and
store materials. Rather than a single piece of equipment, an
automated system is generally made out of several units.
Here are some examples of automated systems:
• Conveyor systems: Automated conveyor systems carry
heavy materials to specified destinations using belts,
flexible chains, or live rollers. It is highly efficient
equipment to move large volumes of material quickly.
• Automated guided vehicles: These vehicles are mobile
robots that follow specific markers or wires in the
floor to move large materials around a manufacturing
facility or warehouse. Vision, magnets, or lasers can be
used as methods for AGV navigation.
• Robotic delivery systems: Robotic delivery systems
transport goods and materials around a facility. These
systems usually help move goods along an assembly
line.
 Safety Procedures Followed
Some safety procedures followed by Bharat Forge :
▪ Always avoid the use of damaged hammers.
▪ Never try to strike a hardened surface with a hardened
tool.
▪ No person should stand in line with the flying objects.
▪ Always use the proper tongs tool to grip and lift
objects according to the type of work.
▪ The anvil should always be clean and free from
moisture and grease while in use.
▪ Always wear proper clothing such as an apron, foot-
wears and goggles.
▪ The handle of the hammer should always be tightly
fitted in the head of the hammer.
▪ Always put out the fire in the forge before leaving the
forging shop.
▪ Always keep the working space clean and tidy.
▪ Proper safety guards should be provided on all
revolving parts.
▪ The Head of the chisel should be free from burrs and
should never be allowed to spread.
▪ During machine forging, always observe the safety
rules prescribed for each machine.
▪ One must have a thorough knowledge and working of
the forging machine before going to operate it.
▪ Wear eye protection when hammering.
▪ Hearing protection is essential.
▪ Change your posture and working height now and
then.
▪ Take breaks every forty-five minutes or so and do
something different now and then.
▪ Do not use your wrist much when hammering; use
your elbow sparingly, your shoulder most. Listen to
your body! Snap the hammer forwards a bit at the
bottom of the swing-let go and stop pushing then and
the hammer will snap itself back up, lifting itself so you
have to do less work.
▪ Keep your forging area separate from the work areas
of others, to reduce the damage to their hearing. As
well as damaging your ears, noise can distract you or
your coworkers, which can lead to injury if they’re
doing something requiring concentration. It’s also just
irritating; to quote the American Association of
Otolaryngology, “some people react to loud noise with
anxiety and irritability, an increase in pulse rate and
blood pressure, or an increase in stomach acid.
▪ Wear safety glasses during hot forging and when
hammering in general. Protective clothing (long
sleeves, leather shoes, a face shield if sparks are flying
around) is also recommended for hot forging.
▪ Tie your hair back if it’s long.
▪ “Other protective measures with hot forging should
include ice for treatment of minor burns, salted water
for heat stress, and a cool room for work breaks”
Challenges Experienced During
Training
There were few challenges encountered during
online Industrial Training .
The main challenge faced that we have to learn new
technology and new things on the digital format due
to COVID- 19 pandemic.
Despite of having pandemic issues going around we
have tried our level best to learn new things from
digital platforms and we did it pretty well.
When the pandemic is over we would be looking
forward to gain some more practical knowledge and
try to apply it.
It was great experience during training. We learned
lot of things and new technologies such as 6-sigma
technology, lean manufacturing, various CAD
softwares etc.
THANK YOU