STEEL CASTING
Forging is a manufacturing process involving the shaping of metal using localized compressive forces. The blows are delivered with a power hammer in open or close die. Forging is often classified according to the temperature at which it is performed: cold forging, warm forging, or hot forging. The metal takes the shape of the die and very strong parts can be produced due to the favorable orientation of the grain. Forging can produce a piece that is stronger than an equivalent cast or machined part. Forgings are usually selected for applications requiring high ductility, impact toughness, fracture toughness and fatigue strength; therefore, forging alloys with inherently high ductility and tensile strength are generally selected.
PRODUCT & ITS APPLICATION:
Forged Metal components are the most widely used, in all the products and manufacturing sectors for wide ranging applications. The majority of forging alloys are in one of seven primary alloy groups: Carbon, micro alloy and alloy steels, Stainless steels, Aluminum alloys,Copper alloys, iron, nickel, or cobalt based heat resistant alloys, Titanium and Magnesium alloys. High-strength alloys have the better tensile strength and fatigue strength. For most load bearing and rotating or high-pressure environment components are made from of specific strong steel alloys that provide significant advantages.For industrial application, primarily steel alloys are forged in hot condition. Brass, bronze,copper, precious metals and their alloys are manufactured for special applications. Each metal requires a different forging temperature.Aluminum, titanium and other nonferrous metal forged parts are mainly used in aerospace,automotive industry and many other fields of engineering, where highest safety standards against failure by abuse, by shock or vibratory stresses are needed. Such parts are for example chassis parts, steering components and brake parts.
DESIRED QUALIFICATIONS FOR PROMOTER:
The promoter with mechanical engineering degree and experience in steel forging industry will be able to be able to manage the project well. The entrepreneur should specialize in specific product range.
MARKET POTENTIAL AND MARKETING ISSUES. IF ANY:
Forged components find wide application in automobile, industrial machinery, Heavy Earth moving equipment, hydraulic systems, mining, process industry for high pressure piping,valves, pumps and turbines, electrical machines, aerospace, nuclear plants etc. to fasteners.Defense and ship building also used large percentage of forged metal products.Most of the forged parts are critical components like shaft, stem, fasteners, auto engine parts like crankshaft, connecting rod, gears, lifting tools and tackles, hydraulic cylinders and valve bodies etc. Huge demand potential exists for forged components in domestic as well exports market.
RAW MATERIAL REQUIREMENTS:
MS and SS steel alloy billets, bars, rods and flats of special forging grade are required for different product to be manufactured by the unit. Carbon steel is available in Grades from C1006 up to C1095, with the carbon increasing from 0.06% to 0.95%. For other alloys specifications are available from BIS and other international bodies. The hot forging products range is considered here. Unit may need to source the quality material sources from appropriate quality suppliers to ensure end quality of products.
MANUFACTURING PROCESS:
Drop forging is a forging process where a hammer is raised and then “dropped” onto the work piece to deform it according to the shape of the die. Press forging works by slowly applying a continuous pressure or force, which differs from the near-instantaneous impact of drop hammer forging. The unit can consider both manufacturing processes one after another. The plant investment may range from 80 to 1500 lakhs depending on forging equipment selection. The process involves cutting of blanks from billet, rods or flats in desired sizes, heating in furnace or with help of induction heating system to a required temperature and forging to the required shape under a drop hammer or press with help of dies. The forged component may be cooled in controlled atmosphere to achieve metallurgical properties. The unit can also machine the components as per the required to achieve the finished product.
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