Advertisement

Defect Rectification in Forging Operation and Optimizing the Process Parameters

  • M. D. Vijaya Kumar
  • U. Vignesh KumarEmail author
Conference paper
Part of the Lecture Notes in Mechanical Engineering book series (LNME)

Abstract

The increased adoption of forging technology for producing a wider range of components has accelerated the need to produce forged products with zero defects. The defects arising during forging process has to be addressed to achieve the industrial quality standards and to meet the customer requirements. The present study has major focus on developing a suitable scientific methodology to eliminate the forging failures. The research includes identifying the various types of defects arising during forging operation, analysing the possible causes of failures and studying the methodology adopted in industries to rectify the defects. Detailed study has been conducted on multiple dimensions like material testing, optimization of design, quality standards analysis. Further, spectrometry and scanning electron microscope test is used to study the nature of failure and to analyse the microstructural defects. Results show that with the adoption of suggested methodologies, the forging defects have been eliminated.

Keywords

Forging defects Optimization of design Spectrometry test Scanning electron microscope test Microstructural defects 

Notes

Acknowledgements

The authors are thankful to Mr. K. Kannathasan, Forging Department, MK Auto components India Ltd., Chennai, for his support during the project. We are grateful to the faculty members of Mechanical Engineering Department of Chennai Institute of Technology for their support and guidance during the research work.

References

  1. 1.
    Statharas, D., Sideris, J., Medrea, C., Chicinas, I.: Microscopic examination of the fracture surfaces of a cold working die due to premature failure. Eng. Fail. Anal. 18, 759–765 (2011)CrossRefGoogle Scholar
  2. 2.
    Tekkaya, A.E., Khalifa, N.B., Hering, O., Meya, R., Myslicki, S., Walther, F.: Forming-induced damage and its effects on product properties. CIRP Ann. Manuf. Technol. (2017).  https://doi.org/10.1016/j.cirp.2017.04.113CrossRefGoogle Scholar
  3. 3.
    Hawryluk, M., Jakubik, J.: Analysis of forging defects for selected industrial die forging processes. Eng. Fail. Anal. (2015).  https://doi.org/10.1016/j.engfailanal.2015.11.008CrossRefGoogle Scholar
  4. 4.
    Kim, D.K., Kang, S.Y., Lee, S., Lee, K.J.: Analysis and prevention of cracking phenomenon occurring during cold forging of two AISI 1010 steel pulleys. Metall. Mater. Trans. A. 30a (1999)Google Scholar
  5. 5.
    Chen, C., Wang, Y., Ou, H., He, Y., Tang, X.: A review on remanufacture of dies and moulds. J. Clean. Prod. 64, 13–23 (2014).  https://doi.org/10.1016/j.jclepro.2013.09.014CrossRefGoogle Scholar
  6. 6.
    Arentoft, M., Wanheim, T.: The basis for a design support system to prevent defects in forging. J. Mater. Process. Technol. 69, 227–232 (1997)CrossRefGoogle Scholar
  7. 7.
    Gariety, M., Ngaile, G., Altan, T.: Evaluation of new cold forging lubricants without zinc phosphate precoat. Int. J. Mach. Tools Manuf 47, 673–681 (2007)CrossRefGoogle Scholar

Copyright information

© Springer Nature Singapore Pte Ltd. 2019

Authors and Affiliations

  1. 1.Department of Mechanical EngineeringChennai Institute of TechnologyChennaiIndia

Personalised recommendations