ESTIMATING, COSTING AND CONTRACTING (3351905)

Experiment No. 5

Title : Estimate forging cost.

Introduction :

Forging
Forging is the process in which metal is heated at sufficiently high temperature to bring it to the
plastic state. During this plastic state desired shape is given by applying sufficient force either by
hand (manually) or by machine.
The shop in which forging is done is known as 'Forging shop'.

Forging Estimation Procedure

Estimation procedure varies from shop to shop and person to person but for a general procedure,
following factors may be considered:

Estimation of Net Weight

For estimation of net weight of the forged component, following procedure is adopted:
a. Break up the job drawing into suitable geometrical section, whose volumes can easily be
calculated by using mensuration.
b. Next, find the value of each section, neglecting rounded corners and taking suitable assumptions.
c. Now, find total volume of material required by subtracting volume of the hollow spaces.
d. Lastly, calculate the weight of the component by multiplying the total volume with its density.

Estimation of Losses
Certain amount of material is lost during different forging operations. The exact estimation of
losses is very difficult, but by practical experience, the losses can be calculated during forging as
accurate as possible. Various losses in forging are:
(i) Tong Loss: While performing forging operations, some length of stock is required for holding
the job in tong. This length is an extra length, which is removed after completion of the job. For
estimation purposes, the weight of the extra length is also considered and is known as Tong loss. 2
to 3 cm of the stock length.
(ii) Scale Loss: The outer surface of the hot metal is generally oxidized, and when hammering is
done oxidized film is broken and falls down in the form of scale. It reduces the dimensions of the
job, and therefore, this loss must be considered for estimation purposes. Generally, it is taken as
6% of the net weight.
(iii) Flash Loss: It is the surplus metal, which comes out between the two meeting surfaces of the
dies. For getting finished product, this surplus metal is required to be trimmed off.
This loss may be calculated by assuming it to be 20mm wide and 3mm thick all around the
periphery of the dies.
Thus, volume of flash loss = periphery x 20x 3 cu mm nearly.

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(iv) Shear Loss: The required sizes of workpiece for forging operations are obtained from long
bars by sawing or shearing. In sawing operation, some material is always lost. If last piece of bar is
not to be required length, it is rejected. This loss of material is taken as 5% of the net weight.
(v) Sprue Loss: The portion of metal between the length held in the tong and the material in the
die is called sprue. This is also a metal loss and can be taken as 7% of the weight.
Thus we can see that nearly 15-20% of the net weight of metal is lost during forging. Therefore, in
estimation their consideration is very essential and total weight will be net weight of job plus sum
of the weight of different losses occurred during forging. Thus this gives the amount of weight of
material required for forging.
Forging is the process, in which the heated at sufficiently high temperature to bring it to the plastic
state desired shape is given by applying sufficient force either by hand ( manually ) or by machine.

Types of Forging :

1. Hand Forging : When forging is done by hand ( manually ), the process is known as
Hand Forging. In case of heavy jobs smith is assisted by a hammer man. Drawing down,
upsetting, bending, punching, swaging and shearing are important hand forging operation.

2. Machine Forging : The processes, in which forging is done by machines are known as
Machine Forging. Machine forging is useful for heavy and complicated jobs requiring large
forces.
Machine forging can be classified as :

I. Smith Forging : In this process metal is heated in suitable forges and then
shaping of the metal is carried out by power or steam hammers and hand tools. In
this method accuracy depends upon the experience and skill of the smith.
With this method, similar pieces cannot be obtained and process require too
much time. This method is used for large and simple types of products.

II. Drop Forging : It is the process of hammering the metal during plastic state in
impression dies. Die is used in two parts; one die is allowed to drop on the other.
The hot metal in the plastic state is thus squeezed between the two dies and thus
forms the desired shape of the forged product. Steam or power hammer can be used,
instead of allowing the upper die to drop on the lower die form certain height. This
process takes less time.
This is generally used, where large number of identical shapes of good
quality forgings are to be produced.

III. Press forging : Very heavy forgings are given proper shape by the presses.
These presses can either be hydraulically operated or be mechanically
operated. Press forging method employs squeezing of plastic metal or metal
in plastic condition and gives the required shape in dies. Pressure excessive
vibrations can be avoided, which may otherwise disturb the machine
alignment by rapid blows of hammer.

Forging Operations :
The shape of material can be transformed by forging with the aid of the following operations :

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1. Drawing Down : It is also known as Drawing Out. This operation is performed to

increase the length of the work piece in forging by decreasing the cross-sectional area.
This process is performed by hammering the hot work piece lengthwise to reduce
cross-section.

2. Up Setting : This is the reverse of Drawing Down operation. In this operation, the cross-
section of the work piece is increased at the expense of length.
This process is performed by hammering one end of hot work piece while other end is
supported against the anvil.

3. Bending : Bending is done by holding the work piece between two fixtures and desired
bend can be given by striking the work piece with the help of hammer. This operation can
also be carried out on the anvil beak.

4. Punching and Drafting: Punching operation is performed by a tool called punch, for
producing holes in the work piece, when it is the hot state; and drafting is an operation
carried on by a special tool known as draft to enlarge the hole.

5. Squeezing : The hot metal is hold between two dies and pressure is applied so the shape
of the material will change as per the internal shape of the die.

6. Setting Down : It is the process of providing the neck to some portion of the work piece
by reducing the cross sectional area.

7. Swaging : Swage is used for shaping the metal in the required shape

Examples :
1. A square bar of 3 cm side and 25 cm length is to be converted by hand forging in to
a bar of hexagonal section having each side equal to 1.5 cm. Calculate the length of
hexagonal bar produced; consider scale loss to be 7 %.

2. 6000 pieces of bolt are to be made by upsetting from 50 mm side and 20 mm height
of square head which shank length is 70 mm. Calculate gross weight of bolt.
Assume density of material is 7.9 gm / cc.

3. 1000 M.S. pins of 4 cm diameter and 10 cm length are to be drop forged from a bar
stock of 5 cm diameter. Calculate the material cost, if bar is available at Rs. 50 per
meter length. Assuming all the possible losses.

4. A circular rod of 50 mm diameter and 300 mm length is to be converted by hand

forging in to a bar of hexagonal section having each side equal to 2 cm. Calculate
the length of hexagonal bar produced; consider scale loss to be 8 %.

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