OPTIMIZING PRODUCTION OF HOT FORGING
INPROCESS WITH REFERENCE TO PROCESS
DEFECTS, WASTE CONTROL, AND DIE LIFE
IMPROVEMENT.
Thesis submitted to
MATS UNIVERSITY, RAIPUR (C.G.)
For the award of the degree
of
DOCTOR OF PHILOSOPHY
in
(MECHANICAL ENGINEERING)
by
(Vijay Baban Jadhav)
(Enrollment No: MU21FPHDMECO2/215307)
Under the Supervision of
Co-Supervisor Supervisor
Dr. Arif Khan Dr. Abhishek Kumar Jain
Dr. Aneesh Somwanshi
(August-2024)
“OPTIMIZING PRODUCTION OF HOT FORGING
INPROCESS WITH REFERENCE TO PROCESS DEFECTS,
WASTE CONTROL, AND DIE LIFE IMPROVEMENT.’’
A
Thesis
Submitted for the Degree
Of
“DOCTOR OF PHILOSOPHY”
In
(MECHANICAL ENGINEERING)
BY
(Vijay Baban Jadhav)
(Enrollment No: MU21FPHDMECO2/215307)
MATS University Raipur, Chhattisgarh
(August-2024)
DECLARATION OF THE CANDIDATE
MATS University Raipur, Chhattisgarh
(August-2024)
I hereby declare that the thesis entitled “OPTIMIZING PRODUCTION
OF HOT FORGING INPROCESS WITH REFERENCE TO PROCESS
DEFECTS, WASTE CONTROL, AND DIE LIFE IMPROVEMENT.” is my
own work carried out under the supervision of (Dr. Abhishek Kumar Jain/Co- Dr.
Arif Khan, Dr. Aneesh Somwanshi with designation and address), approved by
Research Degree Committee.
I further certify that
i. The work done in the thesis is original and done under the guidance of my
supervisor(s).
ii. The work has not been submitted for any other degree/diploma/certificate in
this University or any other University of India or abroad.
iii. I have completed the work as per the norms and guidelines given in the
concerned Ordinance of the University.
iv. Wherever I have used materials (data, theoretical analysis, text and written
material) from other sources, I have given due credit to them by citing them
in the text of the thesis and giving their details in the references.
v. I have put in an attendance of more than 200 days at the research Centre.
A Signature of Candidate
(Vijay Baban Jadhav)
CERTIFICATE OF THE SUPERVISOR
This is to certify that the thesis entitled “OPTIMIZING PRODUCTION OF
HOT FORGING INPROCESS WITH REFERENCE TO PROCESS
DEFECTS, WASTE CONTROL, AND DIE LIFE IMPROVEMENT” is a
piece of work carried out by Mr. Vijay Baban Jadhav under my Guidance and
Supervision for the award of the degree of Doctor of Philosophy in (Mechanical
Engineering) in MATS University Raipur (C.G.). Further, it is certified that the
candidate has put in an attendance of more than 200 days with me.
To the best of my knowledge and belief the thesis,
(1) Embodies the work of the candidate done by himself/herself;
(2) Has been duly completed;
(3) Fulfills the requirements as specified in the ordinance No 26 of MATS
University relating to the award of Ph.D. Degree by the University and is up
to the standard both in respect to the content and language for being referred
by the examiners.
Signature of the Supervisor
(Dr. Abhishek Kumar Jain)
Associate Professor
Department of mechanical Engineering
CERTIFICATE OF THE CO-SUPERVISOR
This is to certify that the thesis entitled “OPTIMIZING PRODUCTION OF
HOT FORGING INPROCESS WITH REFERENCE TO PROCESS
DEFECTS, WASTE CONTROL, AND DIE LIFE IMPROVEMENT” is a
piece of work carried out by Mr Vijay Baban Jadhav under my Guidance and
Supervision for the award of the degree of Doctor of Philosophy in (Mechanical
Engineering) MATS University Raipur (C.G.).
To the best of my knowledge and belief the thesis,
(1) Embodies the work of the candidate done by himself/herself;
(2) Has been duly completed;
(3) Fulfills the requirements as specified in the ordinance No 26 of MATS
University relating to the award of Ph.D. Degree by the University and is up
to the standard both in respect to the content and language for being referred
by the examiners.
Signature of the Co-Supervisor
(Dr. Arif Khan)
CERTIFICATE OF THE CO-SUPERVISOR
This is to certify that the thesis entitled “OPTIMIZING PRODUCTION OF
HOT FORGING INPROCESS WITH REFERENCE TO PROCESS
DEFECTS, WASTE CONTROL, AND DIE LIFE IMPROVEMENT” is a
piece of work carried out by Mr Vijay Baban Jadhav under my Guidance and
Supervision for the award of the degree of Doctor of Philosophy in (Mechanical
Engineering) MATS University Raipur (C.G.).
To the best of my knowledge and belief the thesis,
(1) Embodies the work of the candidate done by himself/herself;
(2) Has been duly completed;
(3) Fulfills the requirements as specified in the ordinance No 26 of MATS
University relating to the award of Ph.D. Degree by the University and is up to the
standard both in respect to the content and language for being referred by the
examiners.
Signature of the Co-Supervisor
Dr. Aneesh Somwanshi
Professor
Department of Mechanical Engineering
ACKNOWLEDGEMENT
Every initiative’s success, aside from mine, depends heavily on the support and direction
of numerous people. I am incredibly appreciative of my supervisors, Dr. Abhisek Kumar Jain,
Associate Professor in the Department of Mechanical Engineering, Professor Dr. Arif Khan, and
Professor Dr. Aneesh Somwanshi. For their patience, unwavering support, and important
guidance throughout my PhD study. Their vast expertise and wealth of experience have inspired
me throughout my academic career and everyday life. I am appreciative of Prof. Dr. Abhisek
Kumar Jain for bringing up the issue and for his helpful advice throughout this project.
I would also like to show my greatest appreciation to my Vice chancellor, MATS
University Dr. K. P. Yadav, Director Dr. Asha Ambhaikar, and HOD Mechanical
Engineering Dr. Virendra Nayak , for their tremendous support and help he made me feel
motivated and encouraged every time. I would like to thank all the members in MATS University
for their kind help and support that have made my study and life in Raipur a wonderful time.
I would also like to express my gratitude to my late father-mother and all my near ones.
Without their tremendous understanding and encouragement in the past few years, it would be
impossible for me to complete my study. Finally, I would like to thank God, for letting me through
all the difficulties. I have experienced your guidance day by day. You are the one who let me
finish my degree.
(Vijay Baban Jadhav)
Signature
COURSE WORKE CERTIFICATS
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Submission Information
Author Name Vijay Baban Jadhav
Title OPTIMIZING PRODUCTION OF HOT FORGING INPROCESS WITH
REFERENCE TO PROCESS DEFECTS, WASTE CONTROL, AND DIE
LIFE
Paper/Submission ID 2212861
Submitted by phdcell@matsuniversity.ac.in
Submission Date 2024-08-08 11:51:41
Total Pages, Total Words 97, 19881
Document type Thesis
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Abstract
The aim of this research work is to optimizing production of hot forging and its defects
by applying some process controlling and product controlling methods. In this research with
help to control technologies the forging defects which are classified with three different way
tocarry, surface defects, inspection defects and also waste controlling analyses are carried out.
The effects of die life on forging process are analyzed in the addition to control in process
defects by adding of one new operation (Hot padding).
To minimize the forging waste in formation of flash by statistical analysis is also covered
in this paper. To control in process defects with die life improvement process with regular
repairing operations such as resink, stress relieving, gauzing operation to control in process
crack with rolling operation corrective action are also covered in this paper This research aims
to optimize production defects in the hot forging process with the initial rolling operation. The
research on rolling forging operations gives broad scopes of these defects in forging operations
such as underfill, cracks formation, and scale pits.
Rolling operations are usually performed under hot forming conditions depending on
the type of motion and shape set-up. There are different types of rolling processes in which
longitudinal rolling forging operation is mostly used in hot and cold rolling forging operations.
Which are reduced material consumption in the forging process. That research helps control
forging defects with regular correction and preventive analyses in rolling operations. In these
researched analyses of different forging product for controlling the forging waste in forging
process.
In forging process forging waste are carry with forging operation which identify by
parting line of products. Parting which defines the product upper and lower die meshing area.
Those extra material are used in forging operation which goes to outside of die that material is
TABLE OF CONTENTS
CHAPTER DESCRIPTION PAGE
NO. NO.
DECLARATION BY THE CANDIDATE I
CERTIFICATION OF THE SUPERVISOR II
ABSTRACT III
TABLE OF CONTENTS IV
LIST OF TABLES VI
LIST OF FIGURES VII
LIST OF ABBREVIATION’S/ SYMBOLS VIII
INTRODUCTION 01-11
01 1.1. Types Of Forging 01-02
1.2 Forging Operations 02-03
1.3 Process Parameters 04-04
1.4 Problem Definition 04-10
1.5. Research Objectives: 10
1.6 .Expected Outcome 11
FORGING PROCESS 12-16
2.1 Types Forging Process. 12-13
02 2.2 Rolling Forging 14-16
FORGING DIE AND DIE LIFE IMPROVING PROCESS. 17-27
3.1 Classification Of Die 17-18
03 3.2 Die Heating Process 18-19
3.3 Design Considerations: 19-21
3.4 Maintenance And Inspection 21-27
04 FORGING DEFECTS ANALYS. 28-36
4.1 Types Of Forging Defects 28-35
4.2 Forging Defects Classification According To Operation 35-36
05 CRACK ANALYSIS WITH ROLLING OPERATION 37-46
CONTROLLED.
5.1 Experimental Setup 37-39
5.2 In Rolling Operation Experimental Analyses. 39-46
06 DEVELOPING NEW HOT PADDING OPERATIONS. 47-53
6.1 Forging Operations 47
6.2 Classification Of Die 48-49
6.3 Rolling Operation Defects- 49-53
07 FORGING WASTE CONTROLLING METHODS 54-64
7.1 Introduction 54
7.2 Design of Experiments 54-62
7.3 Analysis of Yield Ratio of Suspension Arm Shaft. 62-64
08 CONCLUSIONS AND SCOPE FOR FURTHER RESEARCH 65-66
8.1 Conclusion 65
8.2 Scope for Further Researched 66
REFERENNCES 67-69
LIST OF PUBLICATION BASED ON THIS DISSERTATION 70
WORK
FIGURE INDEX
CHAPTER PAGE
NO. NAME OF FIGURE NO.
Fig 01.01 Rolling product 02
Fig 01.02 Rolling edgier 02
Fig 01.03 Blocker con rod 02
Fig 01.04 Finisher con rod 02
01 Fig 01.05 Final product 03
Fig 01.06 Press Machine 05
Fig 01.07 MPI Machine 07
Fig 01.08 Fluorescent Powder 08
Fig 01.09 Shot Blasting Machine. 09
Fig.02.01 Forging Operation 12
Fig02.02 Chart of Forging Process. 13
Fig 02.03 Hand Forging 13
Fig 02.04 Hammer forging. 13
Fig 02.05 Drop Forging 13
02 Fig 02.06 Press forging 14
Fig 02.07 Rolling Forging 14
Fig.02.08 CAD work Sheet Rolling pass of three rolling processes. 15
Fig 02.09 Rolling Operation 15
Fig 02.10 forging operation. 16
Fig 02.11 Raw material colour coding system. 16
Fig 03.01 Open die 17
Fig 03.02 Closed die 17
03 Fig 03.03 Steps In Forging Operations 19
Fig 03.04 Forging Die 20
Fig 03.05 Die Life Analyses 22
Fig.03.06 Scaling Effect. 23
Fig 03.07 Serration Make 23
Fig. 03.08 Resinking 24
Fig 03.09 Grinding Tools 24
Fig 03.10 Consummation of Rod in KG. 26
Fig 03.11 Repairing rod analyses 27
Fig 03.12 Production Shift wise 27
Fig 04.01 Undefiled Job. 29
Fig 04.02 Scale Pit Effects. 30
Fig 04.03 Surface Crack. 31
04 Fig 04.04 Cracking with Flash. 32
Fig.04.05 Depth of Crack 32
Fig. 04.06 Scrap Percentile Du to Forging Defects 33
Fig 04.07 Scrap Percent In Operation. 36
Fig.05.01 Hot rolling process 37
Fig 05.02 Crack Barrel 37
Fig 05.03 Alligator Crack 41
Fig 05.04 Folding Crack 41
Fig 05.05 Non-Uniform Deformation Crack 41
Fig 05.06 Operation considering for work. 41
Fig 05.07 Monthly Scrap report 41
05 Fig 05.08 Operational scrap analyses 42
Fig 05.09 Percentage scrap in products 43
Fig 05.10 Showing Defects Carry in Rolling Operation. 43
Fig 05.11 Crack Formation Job for Overheating and Rolling Operation 44
Fig 05.12Crack Due to Folding Material 46
Fig.06.01 Blocking operation 46
Fig.06.02 Finishing Operation 47
Fig.06.03 Trimming Operation 47
Fig.06.04 Closed Die Profile. 48
Fig. 06.05Trimming Die profile. 48
Fig 06.06. Forging Operation Flow Diagram. 48
06 Fig.06.07 Forging operation defects 49
Fig 06.08 Forging Process Flow Process 49
Fig. 06.09 CAD Diagram Hot Padding Operation 51
Fig. 06.12 Small end measurement 52
Fig. 06.13 Big end twisting analyses. 53
Fig 07.01Trimming die. 55
Fig 07.02 Flash wastage. 56
Fig 07.03 Flash formation Conventional and Parallel. 57
Fig 07.04 Job weight and flash weight 58
Fig 07.05 Suspension Arm (2.84 kg 58
Fig 07.06 Flash suspension arm (0.989Gm) 58
Fig 07.07 Show cut weight job weight and flash weight 59
Fig 07.08 Show final product 165mm 60
Fig 07.09 Show flash of product. 60
07 Fig.07.10 Job Weight 163- mm And Cute Weight 3.2-45 kg 61
Fig 07.11 Utilization of material 61
Fig 07.12 Suspension Arm (2.80 kg) 62
Fig.07.13 Flash suspension arm (0.789Gm) 62
Fig 07.14 Suspension Arm with Flash (3.200 kg) 62
Fig 07.15 Cut length 167mm Cut weight 3.74kg utilization. 63
Fig 07.16 Cut length 165mm Cut weight 3.54kg utilization. 63
Fig 07.17 Cut length vs Cut weight utilization. 64
Fig 07.18 Show final product 64
TABLE INDEX
CHAPTER NAME OF TABLE PAGE
NO. NO.
Table02. 01 Raw material grading system 16
02
Table 03. 01 Indicating Information About Product Details 25
03
Table 03.02 Die Life Experimental Step-up Blocker and Finisher 25
Table 03.03 Die Life Improvement Operational Parameter 26
Table 04.01 Shows the forging defects in the job. 33
04
Table 04.02 Shows the forging defects in the job 34
Table 04.03 Shows the forging defects in the job 36
Table 05.01 Monthly scrap report of products 42
05
Table 06.01 Job Measurement Before Hot Padding Operation 50
06
Table 06.02 Temperature Measurement after Padding 52
Table 06.03 Small End of Job 53
Table 07.01 Cutting length of suspension arm will be Cut length-167 and 54
07
Cut weight-3.74kg
Table 07.02 Cut length 165mm and Cut weight 3.54kg of job. 57
Table 07.03 Job Weight-163mm And Cute Weight-3.245kg. 59
Table 07.04 Cut length, Flash weight, and Job weight. 60
Table 07.05 Experimental design with output and yield ratio for 62
suspension arm shaft.
Table 07.06 Yield ratio relation show utilisation of cut material. 63
Table 07.07 Cut weight, net weight, net weight, yield ratio relation show 64
utilisation of cut material.
LIST OF SYMBOLS AND ABBREVITIONS
SYMBOLS ABBREVITIONS
D Draft Mm
ho Starting Thickness Mm
hf Final Thickness Mm
R Radius Mm
ℽ Bite Angle In Degree.
wo and wf Are The Before And After Work Widths, Mm (In);
Lo and Lf Are The Before And After Work Lengths, Mm (In).
vo Entering Velocity
vf Exiting Velocities Of The Work
Vr The Surface Speed Of The Rolls.
vo Entering Velocity
