Basic of forging

Forging is a process involving the shaping of

metal using localized compressive forces with the
help of tool and dies

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 Types of forging

1 Cold forging

2. Hot forging

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 Cold Forging

Cold forging is a process where metal deform

below then re crystallization temperature

Hot forging

Hot forging is a process where metal deform

above then re crystallization temperature

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 Methods of manufacturing Fasteners

COLD FORGING HOT FORGING

• The quality of cold • The quality of hot
forged products will be forged products will be
normally a precision normally a Semi
grade fasteners and can precision grade
be taken up for further fasteners and has to go
operation like thread through machining,
rolling after forging grinding operation
before finishing.

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 Advantages of cold forging
• Raw material saving
• Scrap is less when compared with regular
machining route
• Mass production
• Precision quality assured

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 Methods of manufacturing Fasteners

1. Extrusion

2. Blow up

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 Methods of manufacturing Fasteners

1. Extrusion

A material pushed through a die of desired cross

section and reduce the size

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 Methods of manufacturing Fasteners

Type of extrusion

1. Single extrusion
2. Half extrusion
3. Trap extrusion

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 How a Bolt is Made
• Raw material is cut • Bolts are heat treated to
• Cone is formed increase the strength of
• Heading is done bolts
• Trimmed • Products are plated in
different colors or
• Pointed phosphated depending upon
• Thread Rolled customer need

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 Fundamentals of a Forging machine

• The raw material is pushed into the quill and cutter by

the feed rolls
• The required amount of raw material is cut by the
cutter with the help of Quill
• The cone pushes the cut off sample into the 1 st die
and cone is formed.
• In the similar way the sample is pushed in to the 2nd
and 3 rd dies by the punches and ejected out by the
knock out pit after formation of the sample
• Trimming normally is taking place in the last station
• Samples are ejected out by the Knock out pin
• Samples are transferred from one station to another
station by the transfer fingers
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 Steels that are used
• Raw material of different specification
which comes in the coil form being
used

• For different grades of products we

have to use different grades of steel
• B) Medium carbon steel
• A) Low carbon steel
• C) Alloy steel

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 Feed rolls and feed tube assembly

• The feed rolls are to changed as per the wire dia

• Select the correct feed rolls with correct groove
• Assemble the feed rolls in the hub
• Check the alignment of feed rolls grooves and feed tube
• Then the feed rolls are to be clamped
• Adjust the feed tube in line with the feed rolls groove
• Replace all the clamps in the feed feeding system

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How to assemble the feed roles

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Feed rolls changing procedure

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 Feed Rollers
• The feed rollers helps to push the wire in to the
cutter through quill bore.
• When both the FEED ROLLERS grips the wire ,
the gap between the top and bottom Roller
should be min of 1.00 mm
• The clamping of the wire rod by the feed rollers
is operated with the help of air pressure
• The air pressure required for the feed roller
depends on the hardness & diameter of the
wire.
• Before feeding the wire in to the feed rolls ,
the wire should be straightened and de -
burred without fail

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Quill and Cutter with wire fed condition

Cutter
Quill
WIRE

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 Installation of Quill and Cutter
• Place the quill in the die block
• Install the cutter in it’s place
• Keep clearance between quill and cutter depending upon the
wire diameter
• The cutter bore and the quill bore must be in line
• The cutter must be adjusted in both the axis at the start of
shearing if it is not in line with the quill bore diameter
• This is a must for the correct feeding of wire without scoring
mark on the wire and also to overcome the short feed problem
in the forging machine
• The product quality mainly depends on the quality of the cut off

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Installation of Quill & Cutter

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 Cut off adjustment
• Alignment of cut off die ( Cutter) with quill is important to get
quality cut off
• Fix the cut – off knife with the bolts and align the cutter bore
with the bore of the quill.
• Use a mirror or insert a small piece of wire rod though the
cutter bore and quill bore.
• After the alignment of the bores tighten the cutter
• If after cutting few pieces . If the feeding is impaired, please
check the alignment of Quill bore and cutter bore
• For getting good cut off and to avoid short feed. cut off station
setting should be perfect.
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 Feeding– feed rolls slipping may be caused by

1. Not enough feed roll pressure

2. Too much of feed roll pressure
3. Quill or Cutter I D , too small
4. Cutter I D smaller than Quill ID
5. Mis alignment of cutter and Quill
6. Wrong wire grooves
7. Worn out wire grooves
8. Kinks in wire
9. Tangled wire

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 Short feed / cut off may be caused by

1. Feed rolls slipping

2. Feed rolls reversing
3. Wire not touching the material stopper
4. Stock gauge set too short
5. Wire straightener improperly adjusted
6. Worn cutter or quill
7. Misalignment of quill and cutter

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 Pusher pin pushing the cut off out of cutter
• The pusher pin helps to push the “ cut off ” sample out of the
cutter.
• The pusher pin should be connected to the cut off die ejector
shaft
• The pusher pin should protrude out 1.00 mm out of the cut
off knife in the fully ejected condition
• If the pusher pin protrudes out too much, it will be cut off
during operation

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 How a good cutoff is achieved
• Wire cut off accomplished with two basic components the
stationary quill and the moving cutter.
• During the feed cycle , wire is fed through the quill and the
cutter. When the wire stops at the material stopper the cutter
moves and shears the wire.
• The quality of the cut off depends on the sharpness of quill and
cutter , clearance between the quill and cutter, type of wire.
• We have to try more or less clearance between quill and cutter
until we good cut off without burr.
• Normal clearance between quill & cutter is between 0.25 mm
to 0.40mm.
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 To change the Heading dies & trim punch
• Remove the die clamp screws
• Remove the dies from the die block along with the knock out
pin
• Place the new die and kick out pin assembly in the die block

Dies

Trim punch
Cutter

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 Kick out

• The function of the kick out mechanism is to push the blank

out of the die after being forged

• A safety bolt is provided in each station and if this bolt fails it

will give signal to the electrical circuit and the machine come
automatically stops in case of over load during ejection

Knock out pin 25

 Kick out Adjustment
• Kick out adjustment is the same for all the
dies except trim station
• Jog the machine until kick out levers are
fully retracted ( top of the lever should be
away from the machine bed frame)
• To move the kick out rod towards the die,
loosen the bushing locknut and turn
bushing clock wise clockwise
• To move rod away from the die , turn the
bushing counter clock wise
• After forging setting, jog the machine to
full kick out position
• Turn the Knock out adjustment screw
clock wise until it is just possible to turn the
kick out rod by hand until it just touches .
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 Knock outs in Die & in Punches
• In order to push the sample out of the die and punches we have
the knock out system
• The knock out pins are in the dies and punch pins are assembled in
the punches
• Knock out pin is a must to eject the sample out of the die
• To prevent the sample going along with the punch , the punch
knock out system in there in the forging machines.

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 Punch side tools

• Punch side tools helps in the formation of the head of a bolt

A) Cone tool B) Monogram tool C) Trimming die

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 Cone tool
• This cone tool is required normally in the 1 st station to pre-
form the cut off sample before heading for the uniform
spread of material of the bolt head

Cone
Shape

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 Monogram
• Monogram is used to form the head
• The S TL trade mark and the product grade formed on the
head of the bolt by this tool .
• This grade mark will change depending upon the grade of the
bolt
• This is the tool which takes the maximum load in the punch
slide

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 Hex shape is achieved by TRIM die

• Bolt across flat is determined by the trim die . The trim die
shears the material for getting the across flat

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 Hex Forming die
• Another method of getting the hex on head of a bolt is by
FORMING the Hex .

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 Setting the trimming station
• Assemble the trim punch in the die
block along with the knock out pin
• Lock the trim punch die case
• Assemble the trim die on the punch
block
• Take back the trim die backwards as
much as possible
• Jog the machine to front dead center
• Set 0.01 to 0.20mm clearance
between the trim die and trim punch
in the maximum dead center position
of the slide
• Check this setting after running about
an hour and adjust if necessary

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 To move the tool forward
• Punch tool forwarding

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 Punch adjustment in both AXIS
• The punch can be adjusted in the Left - right direction
• The punch also can be adjusted in the UP – Down direction also
• These adjustments are required to achieve concentricity limits of
the product as desired

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 Function of transfer
• The transfer finger mechanism receives the part kicked from
the die and transfer that blank to the next die

• The transfer fingers must grip the sample properly for which
following factors to be considered
A) Diameter of the blank
B) Total length of part
C) Size & shape of product

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 Transfer setting
In the multi station headers the transfer setting should be
perfect as these machines are running at high speed.
– The transfer fingers transfers the sample from one station to
the next station and hold the samples till the samples are
guided in the die bores
– Any wrong setting of the transfer can lead to rejection of the
product and also lead to loss of production as we can not run
the machine at optimum speed.
– The center line of the fingers must in the centerline of the dies .

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 Transfer opening cam
• Transfer opening cams controls the opening and closing of the
transfer finger
• They are installed in pairs
• When the roller is in protruding position of the transfer opening cam
, the finger will open
• The transfer fingers close when the roller is down on the circular
portion of the transfer opening cam
• At no point of time the punches should come in contact with the
transfer fingers
• The transfer finger should be in line with the die bore in both the axis
at the forging stroke .

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 Transfer – dropping work piece may be caused by

• Work piece not being kicked clear of die

• Transfer fingers touching
• Broken or bent transfer fingers
• Transfer finger opening rollers improperly set
• Finger closing time set too late
• Finger opening time set too early
• Gripping length insufficient
• Breaking of the transfer fingers may be caused

– A) Finger opening time too late

– B) Kick out pin too long

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 KICK OUT -Breaking Kick out pins may be caused by
• Poor wire coating
• End of kick out pin worn out
• Kick out pin diameter too large
• Back taper in die
• Machining rings in the die bore
• Kick out pin too long
• Breaking kick out breaker studs caused by excess ejection load

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 TRIMMING BURR Under HEAD
• Excessive burr under head may be caused by -
• Trim die adjusted too close to trim punch
• Trim knock out kicking too soon
• Dull or bell mouthed trim die
• Over size trim die
• Too little trim chip clearance
• Excessive trim noise is because the trim die too far from trim punch

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 Markings on head of a Bolt
• Our trade mark – STL
• Product grade mark like 8.8,10.9,12.9
• Month of manufacture

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 Lubrication & coolant
• The header is equipped with a recirculating pressure lubrication and
coolant system
• The same oil is used for Lubrication of the machine parts and
cooling the products.
• Check the oil level in the tanks kept in the front and back of the
machine
• Clean the filters in the tanks at periodic intervals
• Check all the grease point and also check all the lubrication lines are
in tact while the machine is running

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 Operator safety
• Do not wear any loose garment
• Keep away from all the moving
parts of the machine
• Do not put your hand between
the punch and part when the
main slide coming forward
• Do not get in to the machine
when the main motor is
running
• Always try to take the samples
with the help of transfer
• Do not try to work in the
machine if the Brake is not
effective
• oil spillage in around the
machine will lead to accidents

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 Work instructions

• Receive the work order / Job card tools from stores

along with the drawing with the knowledge of
supervisor
• Load the right material – diameter & spec in the coil
stand
• Clean all the machine parts after the removal of the
previous job
• Assemble the tools & then start the change over
• In case of any doubt get the point clarified

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 Operation control panel
• Switch on the “POWER”
• Switch on the LUBRICATION
• For forwarding the slide press the Jog forward . Like wise press the
reverse button for taking back the slide
• Wire will be fed in the machine when the “ feed on “ button is
pressed
• “MACHINE STOP” button will stop the machine if pressed
• To stop the machine in emergency, press “ Emergency Stop “
button

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 First sample approval
• Check whether you have the latest drg
• If dimension is not clear in the drg , pl inform superior
• Set the product to the mean limits
• Check for all dimensions
• Check for raw material spec and diameter
• And product grade
• Forge few pieces in run condition and then offer the sample for
inspection

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 Points to be followed while machine running
• Products to be checked at periodic for all dimensions when the
machine runs
• Operator Quality control charts to be filled up
• Down time of machine to be filled immediately
• To arrange for the right raw material in advance
• To check the product collected in the small bin and then only load O
K products in the big container

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 Heat Treatment of Fasteners
• The bolts and screws are heat
treated in the furnace to get the
tensile strength
– A) Hardening – Material
heated above 860 -880 deg c
and then quenched suddenly
in oil
– B) Tempering – The hardened
fasteners are heated between
400 to500 c and hot air
circulated to remove the
stresses developed due to
hardening

• In both the above operations the

furnace temperature and
traveling time of the product is
important

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 Finishing operation

• The fasteners are coated as

a last operation to increase
the shelf life
• Major finishing operations
are ( General)
– a) Plating
– b) Phosphate
– c) Thermal Blackening
• Apart from the above ,
fasteners goes in natural
finish in oiled condition

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 General Customer Quality complaints
• Go Gauge not answering freely
• Thread found damaged
• Bend in long products
• Soft products found mixed up
• Across flat found wrong
• Spanner slipping
• Different pitch sample found mixed up

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Saving of Raw Material by Forging Process

Minimum scrap

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Thanks….
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