CONTENTS

Table of Contents
Certificate by Company/Institute/Industry .............................................................................. i
Candidate Declaration............................................................................................................. ii
Abstract ...................................................................................................................................iii
Acknowledgment.....................................................................................................................iv
About the company/Industry/Institute ................................................................................v-vi
List of figures .......................................................................................................................... vii

CHAPTER 1: INRODUCTION ................................................................................. 1

1.1 BACKGROUND OF THE TOPIC OF TRAINING ..................................................................... 4

1.2 THEORETICAL E XPLANATION ........................................................................................... 7

1.3 HARDWARE T OOLS: .......................................................................................................... 1

CHAPTER 2 TRAINING WORK UNDERTAKEN ......................................................... 8

2.1 WORKING OF G.S AUTO INTERNATIONAL ............................................................. 8

2.2 SEQUENTIAL LEARNING STEPS: ..................................................................................... 12

2.3 METHODOLOGY: ............................................................................................................. 14

CHAPTER 3: RESULTS AND DISCUSSION .................................................. 24

3.1 FORGING PROCESSES ...................................................................................................... 24

3.2 DIE SHOP OPERATIONS ................................................................................................... 24
3.3 HEAT TREATMENT RESULTS .......................................................................................... 24
3.4 WELDING OUTCOMES .................................................................................................... 25
3.5 TOOLS AND EQUIPMENT OBSERVED DURING TRAINING ............................................... 25
3.6 COMPARATIVE ANALYSIS ......................................................................................... 31
3.7 CHALLENGES AND SOLUTIONS .................................................................................. 32
3.8. LEARNING OUTCOMES ................................................................................................... 32

CHAPTER 4: CONCLUSION AND FUTURE SCOPE ................................ 33

4.1 CONCLUSION ................................................................................................................... 33

4.2 FUTURE SCOPE ........................................................................................................... 33
REFERNCES ........................................................................................................................... 34

1
 HISTORY OF G.S.AUTO

Our journey of excellence started long back in 1938 in pre

independence days when a young man having a great
vision translated his dream into reality steered by sheer
hard work and determination. The entrepreneurship of
our founder, Baba Gurmukh Singh Ji, began with
manufacturing of Bicycle Components, which afterwards
got diversified into manufacturing of Automotive
Components for various motor vehicles.

Further momentum was gained with the joining of his

sons Giani Bhagat Singh (Former Chairman-G.S. Group)
and S. Jagat Singh (Former Managing Director-G.S.
Group). S. Jagat Singh had great marketing skills and
vision to make GS as top brand in auto component market
of India. He formed a small team of 4 dedicated people to
start marketing activity outside Punjab across India. They
remained for months out of their home town traveling all
small and major towns of India to select dealers and
distributors & formed formidable and unparalleled pan
India network of more than 500 Distributors and 10,000

1
Retailers.

Their lifetime knowledge, skills and experience was

handed over by them to their next generation sons. The
participation of Mr. Jasbir Singh Ryait (Current
Chairman & CEO, G.S. Auto) and Mr. Surinder Singh
Ryait (Current Managing Director, G.S. Auto) further
catalyzed growth of the Company. The brothers
complement and supplement each other perfectly, giving a
great boost to the industry

ABOUT G.S.AUTO INTERNATIONAL

GSAUTO is one of the leading and fastest growing

manufacturer of Automotive Suspension and Fastening
Components for Indian ( International Passenger Cars,
Utility Vehicles, Commercial Vehicles (LCVs, MCVs,
HCVs), Multi-Axle Vehicles, Trailers and Special Purpose
Vehicles.

Our manufacturing facilities are located in major

industrial township of Ludhiana in North India &
Jamshedpur in Eastern India, spread over an area of 1.2
million square feet with more than 5,50,000 square feet of
covered area. All our manufacturing facilities are TS
16949 certified.

We are an established leader in all our product segments.

All our products are trusted by National and International
Tier-1 and Automobile Majors Like Arvin-Meritor,
Ashok Leyland, Daimler India Commercial Vehicles Pvt.

2
 Ltd., Hindustan Motors Ltd., Mahindra & Mahindra,
Mahindra Navistar, Maruti Suzuki India Ltd., SML Isuzu
Ltd., Tata Motors, Taco Hendrickson Suspensions Pvt.
Ltd., VE Commercial Vehicles Ltd., VOLVO etc. to name
a few.

We manufacture vast range of casting and fabricated

machined components compatible to various International
vehicles viz. DAF, Daimler, Hino, MAN, Renault, Scania,
Volvo and other Truck and Multi- Axle Trailers for
Overseas Markets. We develop components based on
Customer’s Specifications, Drawings and also provide
Designing Solutions for enhanced Product Performance &
Improved Quality.

CHAPTER 1: INTRODUCTION

1.1 BACKGROUND OF THE TOPIC OF TRAINING

The primary focus of my training was on the various stages of metalworking processes, including
forging, die shop operations, heat treatment, and welding. These processes are fundamental in
manufacturing robust and reliable components used in various industries such as automotive and heavy
machinery.

Importance of Metalworking Processes in Modern Manufacturing

Metalworking processes such as forging, die shop operations, heat treatment, and welding are critical
in modern manufacturing industries. These processes are integral in producing parts that meet stringent
specifications for strength, durability, and reliability. For instance, in the automotive industry, forged
components like crankshafts and connecting rods must endure high stress and wear, requiring them to
be robust and reliable. In the aerospace industry, lightweight yet strong materials are essential, and
processes like forging and heat treatment help achieve the necessary material properties.1

Evolution of Metalworking Techniques

Metalworking techniques have evolved significantly over the years, from traditional blacksmithing
methods to advanced computer-controlled processes. The development of sophisticated machinery and

3
computer-aided design (CAD) tools has revolutionized the way metal parts are manufactured. These
advancements have led to improved precision, efficiency, and consistency in metalworking processes,
allowing for the mass production of complex components with minimal defects.2

Role of Metallurgy in Metalworking

Understanding the metallurgical properties of materials is crucial in metalworking. Metallurgy, the

science of metals, provides insights into the behavior of metals under various conditions of temperature
and pressure. This knowledge helps in selecting appropriate materials and processes for specific
applications. For example, different alloys respond differently to heat treatment, and metallurgical
studies guide the optimization of these processes to achieve desired properties.3

Forging:

Forging is a manufacturing process where metal is pressed, pounded, or squeezed under great pressure
into high-strength parts. This process is typically performed at high temperatures to enhance the metal's
workability. Forging is essential in producing components that require high strength and durability,
often used in critical applications where reliability and safety are paramount.4,5

Forging is a forming process used to strengthen and shape thick sections of cast metal. The process
involves plastically deforming the metal under high compressive forces inside a die cavity, as shown
in Figure 1 below. Deformation usually occurs by repeated strokes or blows applied using hammers,
mechanical presses, or hydraulic presses. The metal is plastically deformed into the shape of the cavity
and is then removed for machining into the finished part. Forging is performed at room temperature,
called cold working, or at elevated temperature to make the metal soft and ductile, called hot working.
6,7

Figure 1.1: Forging- plastically deforming the metal under high compressive forces inside a die
cavity

Die Shop Operations

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The die shop is crucial in creating and maintaining the dies used in the forging process. Dies are
specialized tools that shape the metal during forging. The precision and quality of these dies are crucial
for ensuring the final product's dimensions and integrity. In other words, a die is a specialized
manufacturing tool used in industries to cut, engrave, or shape material, usually with the help of a
press.8

Dies are machine tools commonly employed in manufacturing to shape metal by cutting it into desired
forms or creating external threads on items such as pipes and rods. Dies are designed with chamfered
edges on one side to facilitate the initiation of threads. Die stocks, typically operated manually, are
constructed from materials such as high-carbon steel, high-speed steel, and alloy steel, and they come
in both circular and square shapes. Dies are categorized based on their specific applications, including
stamping dies for press work, casting dies for molding processes, and drawing dies for wire
production.9

Figure 1.2: Die

The different types of dies used in sheet metal operations are as follows:

• Simple Die
• Compound Die
• Progressive Die
• Transfer Die
• Combination Die
• Multiple Die
• Round Split Die
• Adjustable Die
• Die Nut
• Die Plate
• Pipe Die
• Acorn Die

Heat Treatment

Heat treatment involves heating and cooling metals in a controlled manner to alter their physical and
mechanical properties without changing the shape. This process is used to enhance properties such as
hardness, strength, and ductility, making the metal suitable for its intended application.4

5
Heat treatment includes various processes such as annealing, quenching, tempering, and case
hardening. Annealing involves heating the metal to a specific temperature and then slowly cooling it
to relieve internal stresses and improve machinability. Quenching, on the other hand, rapidly cools the
metal to increase its hardness. Tempering follows quenching to reduce brittleness while maintaining
hardness. Case hardening is used to enhance the surface hardness of steel while keeping its interior
softer and more ductile.4

Welding

Welding is a fabrication technique that joins materials, typically metals or thermoplastics, by causing
them to melt and fuse together. This process can be achieved using heat, pressure, or a combination of
both methods. Welding is widely employed in the construction and repair of various components and
structures, resulting in durable and lasting joints.5

Different welding methods include:

• Arc welding: This technique, such as shielded metal arc welding (SMAW) and gas tungsten
arc welding (GTAW), utilizes an electric arc to melt the workpieces and often a filler material
to create the weld.
• Gas welding: For instance, oxy-fuel welding involves using a flame generated by burning a
gas (typically acetylene) to melt the materials together.
• Resistance welding: Methods like spot welding rely on the heat generated by electrical
resistance between the materials to form the weld.
• Laser welding: This method employs a focused laser beam to melt the workpieces precisely,
enabling high-speed and accurate welding.

These techniques offer diverse options for achieving strong and effective welds in various applications across
industries.5

1.2 THEORETICAL EXPLANATION

1. Forging

Detailed Mechanisms of Forging

Forging involves the plastic deformation of metal under compressive forces to produce high-strength
components. The process can be divided into two main categories: hot forging and cold forging. 6

• Hot Forging: This process is performed at temperatures above the recrystallization

temperature of the metal, which allows for the formation of new grains, resulting in improved
ductility and reduced strength. The elevated temperatures reduce the yield strength of the
material, making it easier to deform. Hot forging is particularly important for materials like
aluminum and titanium alloys used in aerospace applications.6

6
 • Cold Forging: Cold forging is carried out at or near room temperature. It results in a high
degree of strain hardening, which increases the strength of the forged part. However, this
process requires greater force to deform the material due to its higher yield strength at lower
temperatures.6

The mechanical properties of forged parts are significantly influenced by the grain structure, which
can be controlled through the forging process. Fine-grained structures, which are desirable for their
improved mechanical properties, can be achieved through careful control of the forging temperature
and deformation rate.1

Influence of Grain Structure

The grain structure of a metal determines its mechanical properties such as strength, toughness, and
ductility. During forging, the metal undergoes dynamic recrystallization, leading to the formation of
new grains. This process refines the grain structure, enhancing the mechanical properties of the
material. For example, fine-grained metals exhibit higher strength and toughness compared to coarse-
grained metals. The controlled deformation and temperature conditions in forging ensure that the final
product has a uniform and desirable grain structure.3

2. Die Shop Operations

Precision and Function of Dies

Dies play a critical role in the metal forming process, shaping the metal under high pressure. The
design and precision of dies are crucial for achieving the desired shape and dimensions of the forged
part.2

• Die Design Principles: The design of dies involves considerations such as stress distribution,
wear resistance, and material flow. Proper die design ensures that the metal flows uniformly
into the die cavity, reducing defects and enhancing the quality of the final product.
• Materials and Coatings: Dies are typically made from high-strength materials like tool steel
to withstand the high pressures and temperatures involved in forging. Advanced coatings, such
as titanium nitride (TiN), can be applied to dies to improve their wear resistance and extend
their service life.

3. Heat Treatment

Phase Transformations

Heat treatment is a process that involves controlled heating and cooling cycles aimed at modifying the
microstructure of metals to enhance their mechanical properties. Key processes in heat treatment
include:

7
 • Annealing: This process entails heating the metal to a specific temperature and then gradually
cooling it to alleviate internal stresses and enhance machinability. Annealing results in a
material that is softer and more ductile.
• Quenching: Involving rapid cooling of the metal from a high temperature, quenching is
employed to increase hardness. This procedure causes carbon atoms to be trapped in a
supersaturated solid solution, resulting in a hard yet brittle material.
• Tempering: Conducted subsequent to quenching, tempering aims to reduce brittleness while
maintaining hardness. This is achieved by reheating the quenched metal to a lower temperature
and then cooling it gradually. Tempering facilitates the diffusion of some carbon atoms out of
the supersaturated solution, thereby decreasing internal stresses and enhancing toughness.3

Thermo-Mechanical Simulations

Thermo-mechanical simulations are used to predict and optimize the outcomes of heat treatment
processes. These simulations take into account factors such as temperature, cooling rate, and material
properties to model the phase transformations and resulting microstructure. By using these
simulations, engineers can design heat treatment cycles that achieve the desired mechanical properties
with minimal trial and error.2

4.Welding

Fundamentals of Welding

Welding is a process that joins materials, usually metals or thermoplastics, by causing coalescence.
This is achieved through the application of heat, pressure, or both. Welding processes can be classified
into several types, including arc welding, gas welding, resistance welding, and laser welding.2

• Arc Welding: Arc welding, such as shielded metal arc welding (SMAW) and gas tungsten arc
welding (GTAW), uses an electric arc to melt the workpieces and the filler material. The
electric arc generates intense heat, which causes the metal to melt and form a weld pool. The
molten metal then solidifies to form a strong joint.
• Gas Welding: Gas welding, like oxy-fuel welding, uses a flame produced by burning a gas
(usually acetylene) to melt the materials. This process is commonly used for welding ferrous
and non-ferrous metals.
• Resistance Welding: Resistance welding, such as spot welding, uses the heat generated by
electrical resistance to join the materials. The heat is produced by passing an electric current
through the metal pieces, causing them to melt and fuse together.
• Laser Welding: Laser welding uses a focused laser beam to melt the workpieces, allowing for
precise and high-speed welding. This process is particularly useful for joining thin materials
and producing high-quality welds with minimal distortion.2

Metallurgical Changes in Welding

8
Welding causes significant metallurgical changes in the weld zone and heat-affected zone (HAZ). The
intense heat from welding can alter the microstructure of the base material, leading to changes in its
mechanical properties.

• Weld Zone: The weld zone consists of the molten metal that solidifies to form the weld. The
microstructure of the weld zone is influenced by factors such as the cooling rate, composition
of the filler material, and welding parameters. Rapid cooling can result in a fine-grained
microstructure with high strength and hardness.
• Heat-Affected Zone (HAZ): The HAZ is the region adjacent to the weld zone that is affected
by the heat of welding. The microstructure of the HAZ can undergo phase transformations,
resulting in changes in hardness and toughness. Proper control of welding parameters is
essential to minimize adverse effects on the HAZ and ensure the integrity of the welded joint.1

Stress and Distortion

Welding can introduce residual stresses and distortion in the welded structures. Residual stresses are
locked-in stresses that remain in the material after welding, while distortion refers to the warping or
bending of the welded components. These issues can compromise the structural integrity and
dimensional accuracy of the welded assemblies.

• Mitigation Techniques: Various techniques can be employed to mitigate stress and distortion,
including preheating, post-weld heat treatment, and proper sequencing of welds. Additionally,
using fixturing and clamping can help maintain the alignment of the components during
welding.3

1.3 HARDWARE TOOLS :

During my training, I gained hands-on experience with various hardware tools used in these processes:

Measurement Tools:

Vernier callipers, height gauge, screw gauge and magnetic dial gauge

Forging Tools:10

• Hammers and Presses: Used to apply the necessary force to shape the metal. These include
mechanical hammers, hydraulic presses, and pneumatic hammers. The hammer, or power
hammer, is a tool most associated with forging. The tool is used to repeatedly hit the metal in
order to deform it.
• Presses use either mechanical or hydraulic pressure to apply continuous pressure on forging
dies. This kind of equipment requires large driving force to vertically squeeze metal into die
cavities with controlled high pressure. Instead of hitting the metal repeatedly to deform it, the
metal is slowly pressed into the dies.10

9
 • Anvils and Swage Blocks: Provide surfaces for shaping metal and creating specific forms and
shapes.

Die Shop Tools:

• CNC Machines: Used for precision machining of dies.

• Grinding Machines: Used for finishing and polishing dies to achieve the required surface
quality.
• Heat Treatment Furnaces: Used for hardening and tempering dies to enhance their durability. 10

Heat Treatment Equipment:

• Furnaces: Used for controlled heating and cooling of metals.

• Quenching Tanks: Contain quenching media (oil, water, or air) for rapid cooling.
• Thermocouples and Pyrometers: Measure and control the temperature during heat treatment
processes.

Welding Tools:

• Electrodes and Filler Materials: Used to add material to the weld joint.
• Protective Equipment: Such as welding helmets, gloves, and aprons to ensure safety during
welding options.5

These tools and techniques are essential for producing high-quality forged components, maintaining
the dies used in forging, improving the mechanical properties of metals through heat treatment, and
creating strong welded joints. The practical experience gained during my training has provided a solid
foundation in these critical manufacturing processes

10
 CHAPTER 2 TRAINING WORK UNDERTAKEN

2.1 WORKING OF G.S AUTO INTERNATIONAL

G.S AUTO INTERNATIONAL is a leading manufacturer of automotive components, with its first
product being the axle. The company has grown significantly and now produces high-quality auto
components that meet international standards. These components are manufactured using advanced,
state-of-the-art technology developed in-house.

Manufacturing facilities
The various manufacturing processes undertaken at G.S AUTO INTERNATIONAL
• Direct Drive Screw Press • Horizontal & Vertical Machining
• Electro Upsetters (MGM)
• Horizontal Forging Upsetters
• Drop Hammer
• Induction Heaters (Horizontal &
Vertical)
• Heat Treating Furnances
• Cold Extrusion Presses
• CNC Induction Hardening Centers
Machines • CNC Grinders

11
 • CNC Turning Centers
• Cold Spline Rolling (GROB)

Machines
• Rack Type Spline Rolling (ROTO
FLO) Machines
• Surface broch

Figure 2.1:Manufacturing Facilities in G.S AUTO

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Product range
G.S AUTO INTERNATIONAL is known for a wide range of products manufactured. The key products are
listed below:

• Rear Axle Shafts • Hollow Spindles

• Torsion Bars • Output & Input Shafts
• Steel Forgings • Machined Forgings
• Wheel Spindles • Yoke Shafts
• Half Shafts • Splined Shafts
• Clutch Shafts • Brake S' Cam Shafts
• Drive Shafts • Track Bars

13
Figure 2.2: Product Range at G.S AUTO

14
2.2 SEQUENTIAL LEARNING STEPS:

Training Overview

The training at G.S AUTO INTERNATIONAL provided hands-on experience across various
departments, including raw material handling, the chemistry lab, the forging shop, the die shop, heat
treatment plants, and machining.

Learning Steps

1. Introduction to the Company and Safety Training

o Gained an understanding of company policies, safety protocols, and operational
procedures.
2. Raw Material Handling
o Observed the processes involved in receiving, weighing, and inspecting raw materials.
3. Chemistry Lab
o Learned about different tests conducted to ensure material quality, such as grain size
analysis, hardness tests, and chemical composition checks.
4. Forging Shop
o Gained insight into the forging processes and the machinery used to shape and form
components.
5. Heat Treatment
o Observed how heat treatment processes alter the properties of forged components to
enhance their durability and performance.
6. Machining
o Learned about precision cutting and shaping techniques used to achieve the desired
specifications of components.
7. Inspection and Quality Control
o Understood the importance of quality checks and the final inspection process to ensure
the components meet required standards.

Detailed Process

The training began with an introduction to the company's operations and safety protocols. Raw
materials were first received at the security gate, weighed, and inspected by the PPC (Production
Planning and Control) department. These materials were then sent to the chemistry lab for quality
checks, including tests for grain size, hardness, and chemical composition.

After passing the quality checks, the raw materials were cut to specified lengths to prepare them for
forging. In the forging shop, components were forged according to their size, shape, and material
specifications. The forged components then underwent heat treatment to alter their properties and
meet specific requirements.

Post-forging processes included fettling and shot blasting to remove excess material from the forged
components. The components then moved to the machining department, where precision cutting and
15
shaping techniques were applied. After machining, the components underwent another round of heat
treatment and a final inspection to ensure they met quality standards.Once the components passed
the final inspection, they were packed and dispatched to customer

Figure 2.3: Steps of processing of raw materials till dispatching

2.3 METHODOLOGY AND TRAINING DETAILS :

I was posted primarily in maintenance and observed working in forging, die shop, welding and heat
treatment.

16
2.3 METHODOLOGY :

• Observation: Close observation of processes and machinery across all departments.

• Hands-on Practice: Active participation in supervised production stages.
• Analysis and Reporting: Thorough analysis of information and preparation of detailed reports
on findings.

1. FORGING SHOP

My primary training area was the Forging Shop, where I gained hands-on experience in: Forging
involves heating metal stock to a specific temperature to increase its plasticity, followed by
operations such as hammering, bending, and piercing to achieve the desired shape. This process holds
a crucial position among various manufacturing methods due to its ability to refine metal structures,
enhance strength by aligning grain direction, and significantly reduce time, labor, and material costs
compared to cutting from solid stock and shaping afterwards.

Figure 2.4: Forging shop

The forging department is pivotal as it marks the beginning of every production cycle. It comprises
two main sections categorized by the mechanisms of their machinery: Forging I, known as upsetting
forging or closed die forging, and Forging II, referred to as drop forging or open die forging. These
sections house the following machines

Forging I:
• Horizontal Band Saws: These machines can handle jobs up to a maximum diameter of
245mm, powered by a 3HP or 2.2 KW motor with 82% efficiency and 1430 RPM. Job
diameters range from 75mm to 125mm.
17
 • Forging Furnaces: Utilized for heating materials for hammer forging, these furnaces
primarily use oil as fuel, providing economical operation with precise temperature and
atmosphere control. Furnaces in this shop are predominantly oil-fired, incorporating brick
arrangements, capable of temperatures ranging from 1123 to 1200 degrees Celsius. They are
equipped with a 10hp motor and can handle a workload of up to 1.25 tons per hour.

• Upset Forging Machines: Available in two types with capacities of 500 tons and 800 tons
respectively, these machines operate pneumatically, utilizing air pressure. They are used for
working on job diameters of 115mm and 150mm.

• Compressors: These reciprocating type compressors produce air pressure necessary for
operating pneumatic machines. They use AWS 100 type oil with a 10-liter oil tank capacity.
Operating pressure is maintained at 7kg/cm²g, with a hydraulic test pressure of 11.55
kg/cm²g.

In Forging I, the production includes axles with a daily output of 650 to 700 units, as well as shafts
with a daily production ranging from 200 to 300 units.

Forging II:
• Forging Furnaces: These furnaces heat raw materials up to 1100 degrees Celsius using rough
furnace oil as fuel. They accommodate batch-type feed and continuous feed mechanisms. A
pusher, powered by an electric motor, assists in moving rectangular workpieces from the band
saws. Furnace oil is regulated with a pump control system.

• Power Hammers: Available in capacities of 6.5 tons and 2.5 tons, these pneumatic hammers
are used for shaping products such as crown gears. They operate with air pressure from single-
stage rotary air compressors, producing compressed air at pressures up to 20 bar. A foot-
operated lever controls the air supply for precise hammer blows.

• Power Presses: Adjacent to the power hammers, these mechanical presses with capacities of
400 tons and 200 tons perform piercing and blanking operations using a crank mechanism.

• Normalizing Furnace: This furnace normalizes products to reduce internal stresses and
improve mechanical properties. Operating at temperatures between 880 to 920 degrees
Celsius, it uses furnace oil as fuel and features three heat zones with specific temperature
settings for each zone. Normalizing takes approximately 20 minutes per cycle.
• Shot Blasting Machine: Used for surface preparation by removing scale from work materials
using metal shots such as malleable iron and cast steel.

• Brinell Hardness Tester: Utilized to measure hardness in Brinell scale before advancing
products to subsequent processes.
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In Forging II, main products include crown gears and bull gears, with a combined production per
shift of 250 and 300 units respectively. The forging department employs a total of 100 workers across
Forging I and Forging II.

Forging Furnaces: The unit utilizes oil-fired furnaces equipped with a pumping unit for oil supply.
The furnace operation involves heating the oil to 90-100 degrees Celsius before it is supplied to the
furnace. A blower heats air to approximately 250 degrees Celsius, which is then directed into the
furnace. Operating temperatures for forging range from 1250 to 1300 degrees Celsius, regulated by
a control valve for oil supply and a butterfly valve for air supply.

Types of Furnaces:
1. Pusher-type Furnace: Features a hydraulic pushing mechanism to insert workpieces into the
furnace, maintaining temperatures of 95-105 degrees Celsius at 12-15 psi pressure.
2. Batch-type Furnace: Processes batches of workpieces individually after heating them to
required temperatures.

The operational workflow in the forging shop involves several key steps:

1. Material Cutting: Upon receipt and inspection, materials undergo cutting to meet specified
dimensions using fully automatic band saw machines. Once cut, materials proceed to the
forging shop.
2. Heating: Materials are heated to forging temperatures (1250-1300 degrees Celsius) in oil-
fired furnaces, which can be of pusher type or batch type. Heating occurs in two stages:
• First stage (Preheating zone): Temperature ranges from 500 to 700 degrees Celsius.
• Second stage (Full heating zone): Temperature reaches 1260-1300 degrees Celsius.
3. Forging: The heated material is shaped using drop hammers, forging presses, or upsetters,
depending on the size and shape of the component.
4. Trimming: Excess material is removed from forged components using trimming presses
post-forging.
5. Heat Treatment: After trimming, components undergo heat treatment. They are placed in
mild steel trays and subjected to processes such as normalizing, hardening, and tempering,
depending on the type of steel and required mechanical properties. Components are then
quenched in a bath to relieve internal stresses induced during forging.
6. Shot-Blasting: Components undergo shot-blasting to remove scales and impurities
accumulated during heat treatment, resulting in a polished surface.
7. Grinding: Final machining involves removing any remaining unwanted material to achieve
a smooth surface finish using grinding machines equipped with grinding wheels.

After grinding, components undergo hardness testing before being transferred to the machine shop
for further machining.

Measuring Instruments Used:

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• Vernier caliper
• Measuring scale
• Measuring tape
• External and internal calipers

Temperature Measurement Instruments:

• Thermocouple: Positioned in furnace heating zones, providing temperature readings displayed on

digital indicators.
• Optical pyrometer: Used for non-contact temperature measurement.

This systematic approach ensures that forged components meet stringent quality standards and
precise dimensional requirements before proceeding to subsequent manufacturing processes

2. DIE SHOP

A die in forging is a crucial tool where heated metal is shaped under pressure to achieve the desired
form. There are two main types of dies:
1. Rough Blocker: This die has larger dimensions to accommodate greater metal flow during
initial forging blows.
2. Finisher: The finisher die has exact dimensions and tolerances required for the final product.
To counter metal flow, a gutter is incorporated around the die cavity.

Die manufacturing is integral to closed die forging, particularly in the automobile industry where
precision is paramount. The process begins with the engineering department issuing component
drawings, followed by CAD engineers creating a 3D model using software like I-DEAS (Integrated
Design Engineering & Analysis Software). Once the die design is finalized in CAD, CNC machining
centers (vertical) are used to fabricate the die. CAM engineers generate CNC programs using
software such as Unigraphics NX, which are then executed by CNC operators. Operations include
roughing, semi-finishing, and finishing, after which the die undergoes inspection using plaster of
Paris (P.O.P) before being delivered to the forging shop for production.

Die Making Procedures:

• Block Selection: Choosing the die block size involves considering the number of cavities
and providing approximately 20 mm gutter space around a cavity sized 100-125 mm. The
block thickness is typically 70 mm for standard pieces, adjusted for clearances.
• Block Preparation: Initial steps include cutting blocks using automatic hand raw cutters,
ensuring both sides are accurately referenced. Machining includes dove-tail marking,
ensuring no tool marks are left, and marking other locations with one machined surface as
the datum.
• Primary Machining: This stage involves facing on a lathe machine, impression turning on
a milling machine, and machining tong holes on both sides for handling. Machining the cavity
can be done using either a milling machine or EDM machine.
20
 • Pressing and Polishing: Grinding with a hand grinder removes tool marks, followed by
polishing with iron stone to achieve a smooth surface finish and facilitate easy die withdrawal.
• Final Inspection: Key checks include dove-tail parallelity and alignment, top surface level,
and dove-tail references to ensure die precision and functionality.

The die shop's meticulous processes ensure that dies meet stringent quality standards, essential for
produ
‘

Figure 2.5: Flow chart of Die shop

21
 3.HEAT-TREATMENT PROCESS

Heat treatment refers to a process involving the heating and cooling of a metal or alloy while it
remains in a solid state to achieve desired properties. Several reasons necessitate heat treatment,
including the relief of internal stresses developed during cold working processes, the hardening and
strengthening of materials, the enhancement of machinability, the modification of grain size, the
improvement of ductility and toughness, the increase in heat wear and corrosion resistance, and the
homogenization of the material structure. This procedure is carried out in a specialized facility where
the product undergoes heat treatment to attain the required hardness. The following processes and
equipment are utilized:
1. Carburizing: Carburizing is a technique to introduce carbon into solid iron-based alloys,
resulting in a hard surface layer. This can be achieved through pack carburizing, gas
carburizing, and liquid carburizing; however, gas carburizing is used here. Components are
heated to 920 degrees Celsius for four hours in a gas atmosphere of CO, H2, and N2, allowing
carbon to diffuse into the outer surface. The goal is to increase surface hardness by enhancing
the carbon content.

2. Tempering: Tempering involves heating hardened components below the lower critical
temperature, specifically at 180 degrees Celsius. This temperature is maintained for about 2
to 2.5 hours, followed by cooling in open air. At this temperature, hexagonal loosely packed
carbides begin to form, and as carbon is rejected, the crystal structure of martensite transforms
from tetragonal to body-centered cubic, characteristic of ferrite. The apparatus used for this
process includes:

Tempering Furnace: This furnace maintains a temperature between 200 and 250 degrees
Celsius. The furnace walls are lined with heating elements, and a motor-driven fan circulates
hot air over the fixtures holding the products.

3. Scale Removal: Scale removal is performed using a shot blasting machine, which cleans the
components after heat treatment. Metal shots are projected onto the surface of the components,
effectively removing scale. The materials used for the shots include malleable iron, cast iron,
or cast steel.

4. Hardness checking: It is being done with the help of Rockwell hardness testing machine.
The harness is kept between 58 & 61 Rockwell hardness.

Purpose of Heat Treatment:

1. Relieve Internal Stresses: Alleviate internal stresses induced by hot or cold working to
enhance machinability.
2. Enhance Mechanical Properties: Improve properties such as tensile strength, hardness,
ductility, and shock resistance.
3. Modify Steel Structure: Alter the microstructure of steel for desired characteristics.
4. Increase Wear Resistance and Corrosion Protection: Boost resistance to wear and tear and

22
 provide anti-corrosive properties.

Measuring Instruments Used in Heat Treatment:

1. Temperature Measurement: Temperature controller/indicator thermocouple for monitoring
furnace temperature.
2. Hardness Measurement: BHN Testing Machine/Micro-measure for checking hardness.

Heat Treatment of Machined Components:

The first stage of heat treatment addresses components post-forging. The second stage involves heat
treating components post-machining, primarily focusing on case hardening techniques. The case
hardening processes utilized include:

• Induction Hardening: Induction hardening is a surface hardening technique that hardens the outer
layers of a metal while keeping the core relatively soft. This is achieved by passing a high-
frequency alternating current through the workpiece, which is placed inside an inductor coil. The
alternating current generates a magnetic field with equal intensity but opposite polarity, causing
the current to penetrate and harden the surface while maintaining a softer core.

• Carburizing: Carburizing involves enriching the surface layer of steel with carbon to create a hard
and wear-resistant exterior. This process aims to enhance the durability of machine parts by
increasing the carbon content on the surface layer. After machining, the parts undergo
carburization and are then sent for final grinding. Various carburizing methods include pack
carburizing, gas carburizing, and liquid carburizing. At GNAU, gas carburizing is performed
using an electrical carburizing furnace.

Heat treatment equipment: -

1) Induction hardening machine (medium – frequency)
2) Carburizing furnace (electrical)
3) Tempering furnace (electrical)
4) Magnetic particle tester (MPT)
5) Hardness Testing machine
6) Grinding machine
7) Gas welding machine

Procedure for Induction Hardening:

1. Machining: Following forging, components are sent to the machine shop for necessary
machining. Once machined, they are prepared for case hardening.
2. Induction Hardening: Post-machining, components undergo induction hardening using
medium and low-frequency induction hardening machines. The primary tooling for these
machines is the induction coil.
3. Hardness Tests: After induction hardening, the components are tested for hardness using a
hardness tester to ensure they meet the required specifications.
4. Checking Case Hardness: The depth of the hardened layer is verified using a micro-measure
device, which checks the case hardness of the components.
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 5. Magnetic Particle Testing (MPT): Components are inspected for cracks that may have
developed during induction hardening. They are first sprayed with kerosene oil and then
examined under ultrasonic light. Any cracks will be highlighted with green light.
6. Tempering: Tempering is performed to eliminate brittleness that may have developed during
heat treatment, thereby restoring the ductility of the hardened components. This process is
carried out in an electrically operated tempering furnace.
7. Grinding: The final step involves grinding, where any unwanted material on the edges is
removed, providing a smooth finish to the components.

Procedure for Carburizing:

1. Carburizing: After machining, components are sent for carburization. This process occurs
in an electrically operated carburizing furnace. During gas carburizing, the workpieces are
placed in an atmosphere of oxygen and a carbon-containing gas. At high temperatures, the
oxygen decomposes the carbon, which then diffuses into the surface layers of the
components. Thermocouples are used to monitor the temperature throughout the process.
2. Quenching: Following carburization, the components are quenched in a quenching tank,
which may use either water or oil as the quenching medium.
3. Hardness and Case-Depth Checking: Once quenching is complete, the components
undergo testing to check hardness and case depth using a hardness tester and a micro-measure
device.
4. Tempering: The components are tempered to remove any brittleness that developed during
carburizing. This is done in an electrically operated tempering furnace.
5. Grinding: The final step involves grinding, where any excess material on the edges of the
components is removed, resulting in a smooth finish.

Figure 2.6: Heat Treatment Process

4.WELDING
Welding is a critical process in metalworking that involves joining two or more pieces of metal
together by melting them and allowing them to fuse. This process can be accomplished through
various techniques, each suitable for different types of materials and applications. During my
training, I observed two primary welding methods: arc welding and gas welding. Below is an
overview of these techniques, their methodologies, and my observations.
24
1. Arc Welding
Arc Welding Overview:
Arc welding is a process that uses an electric arc to melt the workpieces and the filler material. The
electric arc is created between an electrode and the metal, which generates intense heat to melt the
materials. Once melted, the materials cool and solidify to form a strong bond.
Methodology:
1. Preparation:
o Cleaning: Before welding, the metal surfaces to be joined must be cleaned to remove
any rust, paint, or contaminants. This ensures proper fusion of the materials.
o Fit-Up: The metal pieces are aligned and secured in place, usually with clamps or
fixtures, to ensure they remain in the correct position during welding.
2. Setup:
o Equipment: The welding machine is set up with the appropriate settings for current
and voltage based on the material thickness and type.
o Electrode: Depending on the type of arc welding (e.g., Shielded Metal Arc Welding,
or SMAW), the appropriate electrode is selected and installed.
3. Welding:
o Striking the Arc: The electrode is brought close to the metal surface and then struck
to create an arc.
o Welding: The arc is maintained by moving the electrode along the joint while adding
filler material. The heat from the arc melts both the base metal and the filler material,
creating a molten pool that cools to form a solid weld.
4. Post-Weld:
o Cooling: The welded joint is allowed to cool naturally. In some cases, controlled
cooling may be employed to prevent defects such as warping.
o Inspection: The weld is inspected visually and, if necessary, through non-destructive
testing methods like ultrasonic or radiographic inspection to ensure the quality and
integrity of the weld.
Observations:
• Precision: Arc welding requires precise control of the electrode and arc length to ensure
consistent weld quality.
• Heat Control: The process generates significant heat, which must be managed to avoid
overheating and damaging the workpieces.
• Safety: Proper safety measures, including protective gear and ventilation, are essential due
to the intense light, heat, and fumes produced during arc welding.

2. Gas Welding
Gas Welding Overview:
Gas welding, also known as oxy-fuel welding, uses a flame produced by burning a fuel gas (usually
acetylene) with oxygen. This flame is used to melt the metal surfaces and, in some cases, add filler
material to create a weld.
Methodology:
1. Preparation:

25
 o Cleaning: Similar to arc welding, the metal surfaces must be cleaned to ensure a clean
weld.
o Setup: The gas cylinders (oxygen and acetylene) are connected to the welding torch,
and the gas flow rates are adjusted according to the material being welded.
2. Setup:
o Flame Adjustment: The torch is adjusted to produce a neutral or slightly carburizing
flame, depending on the welding requirements.
o Heat Settings: The flame is adjusted to the appropriate size and intensity for the
thickness and type of material being welded.
3. Welding:
o Igniting the Flame: The gases are ignited to produce a flame, which is then directed
at the joint between the metal pieces.
o Welding: The flame heats the metal until it reaches its melting point. If a filler
material is used, it is fed into the weld pool created by the flame. The molten metal
then cools to form a solid weld.
4. Post-Weld:
o Cooling: The weld is allowed to cool naturally.
o Inspection: The weld is inspected for any defects such as porosity or inadequate
fusion.
Observations:
• Flame Control: Gas welding requires careful control of the flame to ensure the correct
welding temperature and avoid overheating.
• Versatility: This method is particularly useful for welding thin materials and can be used for
various metals, including steel, aluminum, and copper.
• Safety: Adequate ventilation and protective gear are necessary to handle the gases and the
flame safely.

26
 CHAPTER 3: RESULTS AND DISCUSSION

3.1 FORGING PROCESSES :

• Quality of Forged Components: The forging process yielded high-quality components, with
a notable uniformity in shape and adherence to specifications. The components exhibited
consistent dimensions and surface characteristics, indicating effective tool use and process
control.
• Efficiency of Tools:
o Mechanical Hammers: The mechanical hammers provided consistent and reliable
impact force, facilitating effective deformation of metal. The repeated blows from
these hammers resulted in well-formed shapes and minimal defects in the forged
components.
o Hydraulic Presses: The hydraulic presses demonstrated precision in applying steady
and controlled pressure. This capability was particularly useful for creating intricate
shapes and achieving uniform deformation, resulting in high-quality forged parts.
o Pneumatic Hammers: Pneumatic hammers allowed for adjustable impact force,
which was beneficial for detailed forging tasks. The flexibility in controlling the force
helped in producing components with precise and intricate features.
• Anvils and Swage Blocks: The anvils provided a stable surface for shaping metal, while the
swage blocks were instrumental in creating specific forms and contours. The combination of
these tools contributed to effective metal manipulation and shaping.

3.2 DIE SHOP OPERATIONS :

• Precision of CNC Machines: The CNC machines operated with high precision, producing
dies with exact dimensions and complex geometries. The automated control and
programming ensured consistent quality and adherence to design specifications, leading to
well-crafted dies.
• Surface Finish of Dies: Grinding machines effectively refined and polished the dies,
achieving smooth and high-quality surface finishes. The removal of excess material and
smoothing of imperfections resulted in dies with excellent surface quality, essential for
successful forging operations.

3.3 HEAT TREATMENT RESULTS :

• Effectiveness of Heat Treatment: The heat treatment processes effectively enhanced the
mechanical properties of the metals. The furnaces maintained precise temperature control,
achieving the desired hardness and strength in the treated materials. The cooling rates from
quenching tanks were appropriate, leading to consistent and reliable material properties.

27
 • Temperature Control: Thermocouples and pyrometers provided accurate temperature
measurements and control during heat treatment. Their readings aligned with the expected
outcomes, ensuring that the metal reached the optimal temperature for achieving the desired
properties.

3.4 WELDING OUTCOMES :

• Quality of Welds: Both arc and gas welding techniques produced high-quality welds. The
welds exhibited strong bonding, minimal defects, and consistent appearance. The choice of
welding technique was appropriate for the materials and applications observed, leading to
successful and reliable welds.
• Impact of Safety Measures: The protective equipment, including welding helmets, gloves,
and aprons, effectively ensured safety during welding operations. The safety gear protected
welders from intense light, heat, and spatter, contributing to a safe working environment.

3.5 TOOLS AND EQUIPMENT OBSERVED DURING TRAINING

Industrial Measurement tools

1. Vernier Caliper
A Vernier caliper is a precision measuring instrument used to measure linear dimensions with high
accuracy. It consists of a main scale and a Vernier scale that allows measurements to be taken to a
fraction of a millimeter or thousandth of an inch, depending on the unit of measurement.
Key components of a Vernier caliper include:
1. Main Scale: A graduated scale fixed along the length of the caliper, typically in millimeters or
inches.
2. Vernier Scale: A sliding secondary scale that allows precise measurements to be read between the
divisions of the main scale.
3. Jaws: The two pairs of jaws used to measure the internal and external dimensions of an object.
4. Depth Gauge: A protruding rod used to measure depths of holes or recesses.

Using a Vernier caliper involves aligning the object being measured between the jaws and reading
the Vernier scale to determine the measurement. The accuracy of a Vernier caliper can be up to 0.02
mm or 0.001 inches, making it suitable for applications requiring precise measurements in fields such
as engineering, manufacturing, and scientific research.

28
 Figure 3.1: Vernier Calipers
2. Vernier Caliper Height Gauge

A Vernier caliper height gauge combines the functions of a Vernier caliper and a height gauge into
a single instrument. Here’s what each of these tools typically does:

1. Vernier Caliper: This is a precision measuring instrument used to measure linear dimensions such
as length, width, and thickness. It consists of two jaws, one fixed and one movable, which can be
adjusted to measure inside, outside, and depth dimensions of an object.

2. Height Gauge: Also known as a height meter, it is used to measure the height of objects and the
depth of holes or grooves. It typically consists of a base with a vertical column (beam) and a
measuring head that can slide up and down the beam for precise height measurements.

A Vernier caliper height gauge combines the features of both instruments. It has a base with a vertical
column similar to a height gauge, but it also includes the sliding jaws characteristic of a Vernier
caliper. This allows the instrument to perform a wider range of measurements, including height,
depth, inside, outside, and step dimensions with high precision.

29
 Figure 3.2: Vernier calipers Height gauge

3. Magnetic Dial gauge-A magnetic dial gauge, also known as a magnetic base dial indicator
or magnetic stand, is a precision measurement tool used primarily in manufacturing,
machining, and mechanical engineering. Its main uses include:

1. Measurement and Inspection: It is used to measure small distances, deviations, and variations in
dimensions with high accuracy. The dial indicator attached
to the magnetic base provides precise readings in
thousandths of an inch or hundredths of a millimeter.

2. Alignment and Setup: - Engineers and machinists use

magnetic dial gauges to align machine parts, workpieces,
and fixtures during setup. By adjusting the position based
on the dial gauge readings, they ensure precise alignment
according to specified tolerances.

3. Quality Control:
- It plays a crucial role in quality control processes by
verifying dimensions and ensuring parts conform to design
specifications. This helps in maintaining consistency and
accuracy in manufactured components.

4. Surface Flatness and Straightness:

- Magnetic dial gauges can also be used to measure the
flatness or straightness of surfaces. By traversing the dial Figure 3.3: Magnetic Dial gauge
gauge across a surface, deviations from flatness or
straightness can be identified and quantified.

5. Checking Runout:
- It is used to check runout in rotating parts, such as shafts and bearings. Runout refers to the

30
deviation from a true rotational path, and precise measurement is essential for smooth operation
and minimizing vibration.

6. Machine Tool Calibration:

- During the calibration of machine tools, magnetic dial gauges are used to ensure that moving
parts such as slides, tables, and spindles are adjusted correctly and move smoothly without
excessive play.

7. Positioning in CNC Machining:

- In CNC (Computer Numerical Control) machining, magnetic dial gauges help in positioning
tools and workpieces accurately, which is crucial for achieving the desired machining accuracy and
dimensional tolerances

4. Screw gauge-
A screw gauge, also known as a micrometer screw gauge or simply micrometer, is a precision
instrument used to measure extremely small dimensions with high accuracy.
Function:
Measurement: Screw gauges are used to measure the thickness, diameter, or depth of small objects,
often to within a thousandth of a millimeter (micrometer accuracy).
Accuracy: They provide much higher precision than vernier calipers, typically measuring up to
0.01 mm or even 0.001 mm.
Reading: Measurements are read directly from the scale on the thimble and sleeve, which are
calibrated to give the precise distance the spindle moves.
Uses:
1. Engineering and Manufacturing: Used extensively in engineering workshops and manufacturing
industries to measure parts, components, and tools with high precision.
2. Laboratories: Commonly found in scientific laboratories for measuring the thickness of thin
objects like wires, foils, and small components.
3. Quality Control: Essential for quality control processes where precise dimensions are critical to
ensure components meet design specifications.
4. Watchmaking and Jewelry: In watchmaking and jewelry industries, where tiny parts require
accurate measurement for assembly and crafting.
5. Educational Purposes: Used in educational institutions to teach precision measurement
techniques and instrument calibration.

Figure 3.4: Screw Gauge

31
Forging Tools
1. Hammers and Presses
Hammers and presses are fundamental tools used in the forging process to shape metal. Their
effectiveness and versatility are crucial in achieving desired metal forms and characteristics.
• Mechanical Hammers: Mechanical hammers are powered tools designed to deliver repeated
impacts to the metal. They operate using a motor-driven mechanism that strikes the metal
with high force. These hammers are typically used for forging tasks that require repetitive
blows to shape the metal. The consistent force applied by mechanical hammers ensures
uniform deformation and helps in achieving precise geometries. Observing their operation, it
was noted that these hammers are especially effective for producing components with
intricate details and consistent shapes.
• Hydraulic Presses: Hydraulic presses use hydraulic pressure to apply force on metal,
gradually pressing it into the desired shape. Unlike mechanical hammers, hydraulic presses
provide continuous pressure, which is ideal for forging large and complex shapes. During the
training, it was observed that hydraulic presses are instrumental in creating detailed and
uniform parts. The ability to control the pressure and rate of application allows for precise
shaping and reduction of defects.
• Pneumatic Hammers: Pneumatic hammers utilize compressed air to deliver impactful blows
to the metal. These hammers are valued for their adjustable force settings, allowing for
flexibility in forging operations. They are particularly useful for tasks requiring variable
impact forces. The pneumatic hammers observed during the training provided effective
shaping capabilities and were beneficial for both detailed and broad forging tasks.
2. Anvils and Swage Blocks
Anvils and swage blocks are essential tools used for shaping metal during forging. They provide
stable surfaces and specific shapes that facilitate various forming processes.
• Anvils: Anvils serve as a robust and stable surface for shaping metal. They come in various
shapes and sizes, each suited for different forging tasks. The anvils observed during the
training were used for flattening, bending, and creating intricate details in forged components.
The solid and flat surface of the anvil ensures that metal can be effectively manipulated and
shaped.
• Swage Blocks: Swage blocks are versatile tools equipped with multiple depressions and
shapes for creating various forms and contours in metal. They are used in conjunction with
hammers or presses to achieve specific profiles and details. The swage blocks observed were
instrumental in creating detailed and complex shapes, making them a valuable addition to the
forging process.

Die Shop Tools

1. CNC Machines
CNC (Computer Numerical Control) machines are advanced tools used for precision machining of
dies. They offer high accuracy and consistency in producing dies with complex geometries.
• Functionality: CNC machines operate by following programmed instructions to precisely

32
 cut and shape materials. The observed CNC machines demonstrated their ability to produce
dies with exact dimensions and intricate designs. The automation provided by CNC machines
ensures that each die is manufactured to the same specifications, enhancing the efficiency and
reliability of the die production process.
• Impact on Die Quality: The precision and repeatability of CNC machines contribute to high-
quality dies. The observed results highlighted the machines' capability to achieve tight
tolerances and detailed features, which are critical for effective forging and manufacturing
operations.
2. Grinding Machines
Grinding machines are used to finish and polish dies, achieving the required surface quality and
smoothness.
• Grinding Process: The grinding machines observed were employed to remove excess
material and refine the surface of dies. This process is crucial for achieving the desired surface
finish and ensuring that the dies meet quality standards. The results showed that grinding
machines effectively eliminated imperfections and provided a smooth, polished surface,
which is essential for the proper functioning of dies.
3. Heat Treatment Furnaces
Heat treatment furnaces are used for hardening and tempering dies to enhance their durability and
performance.
• Functionality: Heat treatment furnaces control the heating and cooling of dies to achieve
specific mechanical properties. The furnaces observed maintained precise temperature
settings and provided uniform heating, which is crucial for the effective hardening and
tempering of dies. The results indicated that the furnaces contributed to the increased
durability and strength of the treated dies.
Heat Treatment Equipment
1. Furnaces
Furnaces are essential for controlled heating and cooling of metals during heat treatment processes.
• Temperature Control: The furnaces observed were equipped with advanced temperature
control systems, ensuring that metals were heated to precise temperatures. This control is
vital for achieving the desired material properties and consistency in heat-treated components.
The results demonstrated that the furnaces provided accurate and reliable temperature
management, contributing to successful heat treatment outcomes.
2. Quenching Tanks
Quenching tanks contain quenching media, such as oil, water, or air, for rapid cooling of heat-treated
metals.
• Cooling Efficiency: The quenching tanks observed were used to rapidly cool metals after
heat treatment. The choice of quenching media impacted the cooling rate and resulting
material properties. The tanks effectively provided the necessary cooling conditions, ensuring
that the metals achieved the desired hardness and strength.
3. Thermocouples and Pyrometers
Thermocouples and pyrometers are used to measure and control the temperature during heat
33
treatment processes.
• Accuracy and Reliability: The thermocouples and pyrometers observed provided accurate
temperature measurements and control. Their readings ensured that the heat treatment
processes were conducted within the required temperature ranges, contributing to the overall
quality and consistency of the heat-treated components.
Welding Tools
1. Electrodes and Filler Materials
Electrodes and filler materials are used to add material to the weld joint, ensuring strong and reliable
welds.
• Application and Performance: The electrodes and filler materials observed were used in
various welding processes to create strong and durable welds. Their performance was crucial
in achieving high-quality welds with the necessary strength and integrity. The results
highlighted the importance of selecting appropriate materials for different welding tasks.
2. Protective Equipment
Protective equipment, such as welding helmets, gloves, and aprons, ensures safety during welding
operations.
• Safety Measures: The protective equipment observed effectively safeguarded welders from
the hazards associated with welding, including intense light, heat, and spatter. The use of
proper safety gear contributed to a safer working environment and minimized the risk of
injuries.

3.6 COMPARATIVE ANALYSIS

Forging vs. Die Shop Tools:
• Tool Efficiency Comparison: The forging tools, including hammers and presses, provided
high-impact and controlled deformation, which was essential for creating forged components.
In comparison, die shop tools such as CNC machines and grinding machines ensured
precision and surface quality in die production. Both tool types were effective in their
respective roles, with forging tools focusing on shaping and die shop tools on precision
machining and finishing.

Heat Treatment Methods:

• Furnace vs. Quenching Tanks: The heat treatment methods observed demonstrated their
effectiveness in achieving desired material properties. The choice of furnace and quenching
medium influenced the final properties of the metal. For instance, appropriate furnace settings
ensured optimal hardness, while quenching tanks provided effective rapid cooling, resulting
in consistent material characteristics.

Welding Techniques:
• Arc vs. Gas Welding: Arc welding and gas welding were compared based on their outcomes.
Arc welding provided strong and reliable welds suitable for various applications, while gas

34
 welding was effective for specific tasks requiring precise control. Both techniques had their
advantages, with arc welding being more versatile and gas welding offering a more controlled
approach for certain materials.

3.7 CHALLENGES AND SOLUTIONS

Issues Encountered:
• Forging Challenges: Some challenges included tool wear and difficulties in achieving
precise shapes. Tool maintenance and calibration were addressed to mitigate these issues,
ensuring consistent results in forging operations.
• Die Shop Difficulties: Challenges in the die shop included calibration issues with CNC
machines and grinding inconsistencies. Solutions involved regular maintenance and
adjustment of machinery, leading to improved precision and surface quality in die production.
Heat Treatment Concerns:
• Temperature Control Problems: Issues related to temperature control included occasional
deviations from target temperatures. These were resolved by fine-tuning furnace settings and
regularly calibrating thermocouples and pyrometers to ensure accurate temperature readings.
Welding Difficulties:
• Welding Defects: Defects such as weak welds and poor fusion were observed during
welding. Corrective measures included adjusting welding parameters and techniques to
improve weld quality. Additionally, continuous monitoring and feedback helped enhance the
welding process.

3.8. LEARNING OUTCOMES

Skills Acquired:
• Forging Techniques: The training provided valuable insights into effective forging
techniques, including the use of various hammers and presses. Skills in shaping and
deforming metal with precision were significantly enhanced.
• Die Shop Proficiencies: Competencies in die shop operations included precision machining
with CNC machines and achieving high-quality finishes with grinding machines.
Understanding the importance of accurate die production and surface quality was a key
learning outcome.
Understanding of Heat Treatment:
• Heat Treatment Practices: Knowledge of heat treatment practices, including temperature
control and cooling methods, was deepened. The ability to achieve desired material properties
through controlled heating and cooling was a crucial learning outcome.
Welding Expertise:
• Welding Skills: Skills in welding techniques, including arc and gas welding, were developed.
Understanding the strengths and applications of each welding method, along with the
importance of safety measures, contributed to overall expertise in welding processes.

35
 CHAPTER 4: CONCLUSION AND FUTURE SCOPE

4.1 CONCLUSION

The results section provides a comprehensive overview of the observations made during the training,
including

The training provided a thorough understanding of various metalworking processes, including

forging, heat treatment, and welding. Through hands-on experience with tools and equipment,
including hammers, presses, CNC machines, and welding tools, significant insights were gained into
the operational and technical aspects of these processes. The training allowed for a practical
application of theoretical knowledge, enhancing proficiency in using key tools.

Challenges encountered during the training were addressed through problem-solving approaches,
demonstrating adaptability and critical thinking. Overall, the training contributed to a deeper
comprehension of metalworking processes and equipped with the skills needed to execute and
optimize these processes effectively.

1.2 FUTURE SCOPE

The future scope of my learnings from this training is promising and expansive. With a solid
foundation in forging, heat treatment, and welding processes, I am well-equipped to delve deeper
into advanced manufacturing techniques and innovations

The skills acquired enable me to explore emerging technologies in metalworking, such as additive
manufacturing and smart materials.

Additionally, understanding the intricacies of tool design and heat treatment opens opportunities for
optimizing production processes and improving product quality. My training has also prepared me
to contribute to research and development in material science, potentially leading to advancements
in industrial applications and sustainability.

36
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1. Smith WF, Hashemi J. Foundations of Materials Science and Engineering. McGraw-Hill

Education; 2011.

2. Kalpakjian S, Schmid SR. Manufacturing Processes for Engineering Materials. Pearson;

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3. Callister WD, Rethwisch DG. Materials Science and Engineering: An Introduction. Wiley;
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4. Forging Industry Association. Available from: http://www.forging.org/

5. Mechanical Engineering blog. Available from: https://mechanicalengineeringblog.com/

6. Mouritz AP, editor. Processing and machining of aerospace metals. In: Introduction to
Aerospace Materials. Woodhead Publishing; 2012. p. 154-72. ISBN 9781855739468.
Available from: https://doi.org/10.1533/9780857095152.154

7. Available from: https://www.sciencedirect.com/science/article/pii/B9781855739468500078

8. Importance of die and tool design process in engineering. Available from:

https://www.sphinxworldbiz.com/blog/importance-of-die-and-tool-design-process-in-
engineering/

9. Types of dies. Available from: https://testbook.com/mechanical-engineering/types-of-dies

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methods/#What_is_The_Metal_Forging_Process.

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