CASTING
SKETCH OF SAND MOULD
Pouring basing
Open riser
Vent
Flask
Sprue
Blind riser
Cope
Parting Line
Core
Sand
Runner
Mould Cavity
Drag
Well
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INTRODUCTION
One of the most popularly metal forming in manufacturing process is forging. The history of forging is go
back to around 4000BC. Material is transformed via plastic deformation stage with low waste generation
process. Forging is a process that presses a metal under pressure into strong parts called forgings.
Different techniques are applied to obtain simple and complex parts. These days tools, operations and
methods are highly automated and power driven. This study describes the development and future trends
in forging operations. The use of artificial intelligence(AI), computer Numerical controls (CNC), use of
robotics, power hammers made the forging ensure efficient and highly operation performance in
manufacturing process
This technique depend on the temperature and are named as warm, cold and hot operation. Conventional
forging includes open die, impression die and fleshless forging. Forging is effective methods to produce
various shapes of discrete parts such as bolts, rivets, gears ….etc. forged The parts manufactured by
forging is better than the casting. Following techniques can be seen in forging operation.
IMPRESSION DIE FORGING
The transferring form mold to die, forging and trimming are highly mechanized and This operation is now
modified to auto forging. This include the computer controlled perform (CCP) forging method. Traditional
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forging process produce small volume but the CCP made the process autonomously. The programming is
used to communicate and stored and can be used in later stages. In the later this programme can be
changed to obtain any specific changes in the parts.
Press forging
Press forging is the process of shaping material by placing between two dies using mechanical or hydraulic
pressure. In last decade this technique used to manufacture thin walled electronic components of
magnesium alloys. The process squeeze a thick sheet along pressure direction which is different from the
traditional way.
Open die forging
Open die process is used in mass production. Therefore this has been developed to become cost effective.
The forging instruments are therefore design to use with little or no waste material. Only other hand open
die forging are designed to produce any shape or type of metals.
Drop forging
Advancement of hot tool drop forging operations obtained excellent wear resistance for different
industrial applications.
Upset forging
This technique involve increase the cross section of work piece along its length. Recently upset forging is
used to produce cylindrical billets having different frictional conditions.
Roll forging
Roll forging is now used to reduce the cross section and distribution of metal billets which reduce
extensive work using forging presses or hammers.
Forging industry in the future
Die design and modelling software help to improve the life of the tooling. Advanced prototyping will be
used to forge product design. This will enhance the operations and the speed of the process. On the other
hand computer models improve the quality, efficiency in the future while reducing the cost and time. This
computer codes and software will be available to improve the microstructure and mechanical properties.
Similarly advanced lubrication increase the die life and process efficiency, product quality, reliability and
predictability. Therefore in order to keep up with the technology, forging industry needs to address the
areas such as modelling, design of the die, materials, process controls, sensors… …etc. on the other hand
internet of things (IOT) will revolute the forging operations.
In the future forging process will be done with clean, environment safe and eco-friendly. The operation
will be automated and high level technical solutions will be used for product manufacturing and high
dimensional accuracy and consistency can be achieved. Forge companies will be more in the virtual with
cloud communication and will be able to successfully create products and communicate with the
customers.
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