Design and Fabrication of Multi-Die Forging Machine. (original) (raw)

IJERT-Study on Development of an Automated Open Die Forging Machine

International Journal of Engineering Research and Technology (IJERT), 2019

https://www.ijert.org/study-on-development-of-an-automated-open-die-forging-machine https://www.ijert.org/research/study-on-development-of-an-automated-open-die-forging-machine-IJERTCONV7IS07027.pdf Forging is a prime process of the manufacturing industry. After casting the next process may be considered either machining or forging process. In primary metal forming process, forging provides very good mechanical properties. In all the engineering and diploma colleges, a basic laboratory on forging will be conducted. The objective of this paper is to identify the problems in forging laboratory and developing the forging model which will operate automatically. Before designing the automated forging system, a detailed literature survey has been conducted and identified that the pneumatic force is used for forging but drop forging is one of the simplest and easiest way for forging. In drop forging certain mass of the hammer is dropped from the specified height to get the desired shape for the heated blank. Automated forging model which mainly consisting of Frame, Lever, Hammer, Anvil, Cam, Motor and Gear box. The lever is fixed to the frame with the hinge; the hammer is connected to the end of the lever which will be lifted to the desired height with the help of cam. Cam and lever arrangement uses the lever mechanism i.e. Mechanical advantage. The cam is operated by the motor. Here the gear box is used to reduce the speed by 1:50. The cam clamps were used to alter the lift height of the hammer depending on the work piece material to be forged. Tests were conducted, to check the proper alignment of hammer with the anvil. Simple forging models were prepared both by manual method and by using automatic forging machine. The models prepared were giving satisfactory results. By this machine, with minimum cycle time number of components with accurate dimensions, very good mechanical properties were obtained.

Design and Development of Multi-Profile Sheet Forming Machine for Small Scale Industries

Materials Today: Proceedings, 2017

Sheet forming machine is a general device in machine shop, which has utilized to bend the sheet metal in various profile. It is generally used in different industrial operations like bending a sheet metal in different profile like corrugated shape, square shape, half hexagonal shape etc. There are many kind of sheet forming machine that can found in small and large scale industries which are not feasible for forming a sheet with multi profile Hence fulfil the gap project has taken, and by conducting literature review, it was identified that there is lack of machine to form a small pieces and also identified the cost of the machine as too high. To understand the type of user and machine environment, data collection process is carried out with small scale industries. By considering customer requirement QFD and PDS was generated for Machine. To solve the current problems and issues with the user workplace, five concepts of Multi Profile Sheet Forming Machine were generated. The best among the five concepts was selected as final concept by weighted ranking method and the geometric model of final concept was generated. To validate the machine Kinematic simulation, static and modal analysis has been done. A working mock-up 1:1 scale multi profile sheet forming machine was made to validate the design with the user group and feedback is positive and satisfactory.

FABRICATION OF MULTI PROCESS MACHINE

The various machining process in manufacturing industries are carried out by separate machining machine. It need more space requirement and time with high expenses. But the fabrication of multi operation machine, which contains three operations in a single machine. The operations are namely drilling, slotting and shaping. It is a new concept specially meant to reduce the work time and save the cost. Instead of using a slotting machine we are using the special arrangements for slotting operation in the drilling machine same for the shaping operation also, so we can save the investment cost of exceed slotting and shaping machine in the industries. The machine operates through drilling machine with the bevel gear and cam mechanism arrangements. Hence exactly we can carry out three operations in this machine, namely drilling, slotting and shaping. It is a simple in construction and easy to operate. Driller, Bevel gear, Drill bit, Chuck, Cam mechanism, bearings, slotting tool, shaping tool and guide are the main parts used in this machine.

DESIGN AND FABRICATION OF PROTOTYPE OF MULTIPURPOSE MACHINE FOR SHEET METAL OPERATIONS

Sheet metal is basically a thin sheet of metal by using several operations. Nowadays it has become one of the most important and fundamental forms in metalworking.[10] the advantage of sheet metal is that it can be bent into variety of desired shapes. Lots of everyday objects are being manufactured using sheet metal. Sheet metal is mainly used for various aerodynamically shaped car bodies, airplane wings, architecture and many other applications.[9] dent removing/rolling, cutting and v-grooving are the most widely used operations in the fabrication industry. The conventional machines could only carry out any of the above operations simultaneously. If these operations can be done on a single machine, it would not only make work quite easy and less tedious but also increases profitability .moreover, conventional machines are often hand operated for small scale industry applications. Also the time taken on these separate machines that is the overall lead time decreases by making them power operated, resulting in lower cost and higher productivity. Our project is to encompass these operations onto a single machine successfully.

Case study for high speed milling of forging dies cavities

This paper shows practical data and tests which have been carried out to evaluate some changes brought up by the high speed milling of hardened die forging cavities. Work has been developed inside a tooling shop by following its available capacity and resources. Main objects of this study were to provide remarkable evidences that prove reduction on manufacturing time of forging dies and also economical results achieved with its proper development. High Speed Machining (HSM) has been showing many advantages for manufacturing and cavities restoring of forging dies. According to chosen configuration and performing a global analyzes of the process, technical and economical demands have been met and manufacturing process of forging dies has become much faster.

An Overview of Forging Processes with Their Defects

The objective of this paper is to identify and understand the various forging processes and to investigate the various forging defects. Initially, some important forging terms that are widely used in this field are discussed. A brief description about classification of forging process on the basis of temperature of work piece (hot, cold, and warm forging) and on the basis of arrangement of dies (open, impression and closed-die forging) is given. Die design parameters, die material requirements and selection of proper die materials are briefly discussed. Also, briefly described the forging equipments (hammer and press). Factors for selection of forging machine, characteristics and common applications of forging are given. Forging defects those are repeatedly occurring are discussed along with their causes and remedies. Then the fish-bone diagram is used to explore the possible causes of defects like unfilling, mismatch and scale pits through a brainstorming session and to determine the causes, which may has the greatest effect. Finally, it is concluded that the forging process gives better quality product than the part produced by any other processes with implementation of preventive actions to reduce the rejection rate.

An Industrial Application: Improving Performance of an Old Forging Press

MM Science Journal

Forging is one of the most important production methods in applications where the disadvantages of machining are not desired. However, the possibility of micro-cracking in the material at the end of the forging process should be considered. The main constraints here are the aging of hydraulic systems and possible casting defects. Therefore, in this study, the modernized process of an old forging press with a capacity of 30000 kN was carried out. For this purpose, the capacity of the forging press has been increased by modifying a new generation pump and hydraulic accumulator group. Thus, by increasing the cycle time of the hydraulic forging press, it is known that effective forging can be performed in a shorter time (from 1.7 to 1.3 seconds). When the modernization results are examined, it is seen that the necessary forging processes can be completed before the material cools down to the critical temperature.

Decomposition of forging die for high speed machining

Corr, 2009

Today's forging die manufacturing process must be adapted to several evolutions in machining process generation: CAD/CAM models, CAM software solutions and High Speed Machining (HSM). In this context, the adequacy between die shape and HSM process is in the core of machining preparation and process planning approaches. This paper deals with an original approach of machining preparation integrating this adequacy in the main tasks carried out. In this approach, the design of the machining process is based on two levels of decomposition of the geometrical model of a given die with respect to HSM cutting conditions (cutting speed and feed rate) and technological constrains (tool selection, features accessibility). This decomposition assists machining assistant to generate an HSM process. The result of this decomposition is the identification of machining features.

Advancement in Forging Process: A Review

Forging is the technology of shaping the metal piece into the desired shape. This technology is widely used in the industry for making the well-defined shape of the metal. From using the simple hammer and anvil in the 12th century for making a simple shape to making the complex shape in present times forging witnessed the various advancements in its ways. In the recent times, there had seen much advancement in the processes of forging technology. In this review paper, various processes are discussed which bring the revolution in the field of forging technology.