Analysis of Forging Defects for Quality Improvement in Forging Industries

The aim of my work is to understand and to investigate the forging defects. Initially some very important terms related to forging are discussed. A brief description about classification of forging process on the basis of temperature (hot, cold and worm forging) and on the basis of arrangement of dies (open, impression and closed-dies forging) is given. Die design parameter, die material requirements and selection of proper die material are briefly discussed. Also, briefly described forging equipments (hammer & press). Forging defects those are repeatedly occurring such as underfill is centre point of the work. Non-linear FEM analysis based process modeling is applied on crankshaft with aid of DEFORM. By analysis of velocity vectors, defects such as laps, folds and underfill in forged crankshaft were predicted. To identify forging defect and for better process design, flow stress of crankshaft material, AISI 5140, is studied. Then fish-bone diagram was used to explore the possible cause of forging defects like underfill, mismatch and scale pits.