A REPORT ON FORGING AND RELATED PROCESSES

BY

Vaibhav Shetiya 2014A4PS325G

AT Aurangabad Electricals Private Limited, Aurangabad, Maharashtra

A Practice School-1 Station of Birla Institute of Technology and Science,

Pilani July, 2016 Station: Aurangabad Electrical Private Ltd.
Centre: BG Fastening And Industries

Private Ltd.

Duration: 2 months Date of

start: 23/06/2016

Date of Submission: 12/07/2016

Title of the Project: Study on Forging and Related Processes.

ID No: 2014A4PS325G

NAME: VAIBHAV RAJENDRAKUMAR SHETIYA

DISCIPLINE OF STUDENT: MECHANICAL ENGINEERING

NAME AND DESIGNATION OF EXPERTS:

MR. MAJUMDAR(CORPORATE HR)

MR. HANDA(BUSINESS HEAD)

MR. MURTY(PRODUCTION HEAD)

MR. YADAV(HR HEAD)

MR. SINHA(OPERATIONS HEAD)

MR. PAWAR(ASSISTANT HR)

MR. PATIL(MATERIAL SUPERVISION)

NAME OF THE PS FACULTY: DR. BIBHAS RANJAN SARKAR

KEY WORDS:
PROJECT AREA: PRODUCTION TECHNIQUES,DESIGN,MATERIAL SCIENCE,ETC.

ABSTRACT: THIS REPORT GIVES A BRIEF ON THE FORGING AND

THREADING/ROLLING PROCESS AND THE MACHINES USED FOR IT ALONG
WITH HOW THE RAW MATERIALS ARE SELECTED FOR THE SAME.IT ALSO
GIVES A OVERVIEW ON THE DIFFERENT FORGED PRODUCTS AND HOW THEY
ARE REPRESENTED WITH DIFFERENT MECHANICAL DRAWINGS.FINALLY AFTER
UNDERSTANDING THIS IT BRIEFS ON A PLAN FOR NEW PRODUCT
DEVELOPMENT.

Acknowledgements

The author is grateful to Mr. Sinha (Operations Head, Surface Treatment) for
the time he devoted out of his busy schedule to listen to new ideas and to
guide in all technical matters. He is thankful to Mr. Patil for helping out in
touring the facility and teaching how the process happen.

The author is also indebted to Dr. Bibhas Sarkar (Faculty, BITS Pilani) for
arranging and organizing a highly educational program and sharing and
shaping opinion on diverse matters; to Mr. Majumdar (Corporate HR) for his
wisdom and career advice; to Mr. Yadav (HR Head, BG Fasteners) for his
constant support in all matters; to Mr. Handa (Business Head, BG Fasteners)
for his inspirational talk; to Mr. Murti (Production Head, BG Fasteners) for
laying out the rules and regulations for safety and conduct.

Author also wishes to thank his colleague Vaibhav Shetiya (BITS Pilani, Goa
Campus) for making the otherwise sometimes-boring-time less burdening.

TABLE OF CONTENTS
1. Introduction

2. Selction of Raw Materials

2.1 Grade

2.2 Property Class

3. Forging and Threading Process and Machines

3.1 Nut Forming Machine

3.2 Bolt Forming Machine

 3.3 Bolt Rolling Machine

3.4 Nut Tapping Machine

4. Mechanical Drawings:

4.1 Product Drawing

4.2 Forging Drawing

4.3 Tool Drawing

5. New Product Development Plan

6. Conclusions And Recommendations

7. Appendices

8. References

9. Glossary

INTRODUCTION
This report consists the description and the
operations done on the rolling and forging machines.
Also it considers how raw materials are selected and
the description of the various drawings and their use
in making nuts and bolts.Finally it uses the insights
learnt and summarizes by developing the new
product development process.
BAGLA GROUP FASTENERS (BGF) is the joint venture
of BAGLA Group with Fontana Group, the leading
manufacturer of fasteners in Italy. It specializes in
making hexagonal, flange, collar and nylock fitted
nuts and various sizes of bolts of varying sizes.
A lot of sequential steps have been employed to
manufacture these fasteners. For both nuts and bolts
the steps right from phosphating, wire drawing, cold
forging, threading/rolling, heat treatment, surface
treatment and packing.
I had been given to the project of studying the
forging and rolling machines. Following is a brief
account on their working principles.
is a operation by which the desired shape is given to
the workpiece by pressing it by a hard punch. There
are two kinds of forging machines at BGF:
1 .NUT FORMER MACHINE: In this process
hexagonal nylock nuts are produced with the help of
cold forging operation.

MODEL: WF24B6S
CAPACITY: M12 to M16
The processes required for flange nut forging are
Forging
Tapping
Surface Finish
Nylock Fitting
Operation: It consists of a 6 die and 6 punch
operation system. The wire after phosphating and
drawing enters the nut forming machine with the
help of feed rollers and and wire straightener. The
wire is cut for the required length and is held in the
die with the help of fingers. The first punch punches
it and then it is knocked out and transferred into the
second die with the help of transfer fingers. The
punch operates again and this process continues till
the nut reaches the sixth die and punch. The sixth
punch is the piercing one and the sixth die is the
monogram.
This machine operates on two speed namely high
and low.It depends on the type of nut.
Low speed is normally 70 rpm.

2. BOLT FORMING MACHINE: This machine is a 3-4

progressive dies forging machine that is designed for
cold forging.
Cut off die max-10mm
Cut off length max-220mm
Kick out length-215mm
Forging Power-70 tons
Feed Roller: Grooves of feed roller must be
compatible with diameter of wire rod. Both feed
rollers grip the wire rod, gap should be about
1mm.
Cut off knife: If after cutting a few blanks, wire
feeding is impaired or if there is cutting marks
on the blank, adjust the alignment of the cut-off
die and knife.
Pusher Pin: The pusher pin should be connected
tightly on the cut-off die ejector shaft. The tip of
the pusher pin should have a chamfer. The
pusher pin should protrude 1mm out of the cut-
off knife in fully ejected position.
Kick out system: As the name suggests the KO
system kicks out the blank that goes into the die
with the help of kick-out pin.
INSPECTION AND MAINTENANCE:
For the best possible result from the bolt forming
machine should be inspected and maintained
regularly.
Air Pressure-4-6 kg/cm2
Cool oil-Check weekly.
Metal chip clogged in waste slot-Visual per week.

Rolling and threading machines: These machines are

used to roll the bolt and internally thread the nuts of
the given pitch.
3. THREAD ROLLING MACHINE: It is a simple cold
forging process confined almost entirely for external
threads.
Hardened steel dies are used to roll the threads. The
threaded face of dies are pressed against the
periphery of a plain cylindrical block and re-form the
surface of blank into threads as the blank rolls on die
faces.
No material is removed and consequently no chips
are produced.

OPERATION: In this machine the bolts which are

formed with the help of bolt forming machine are put
in through the hooper. Then they are transported
with the help of line. The chopper is then used to
release one piece at a time. Then the pusher is used
to transport the bolt to the die where it is externally
rolled
FLANGE NUT TAPPING MACHINE: The scope of
this machine is applicable for all flange nut for
internal threading.
The sequence of the operation can be summarized as
from hooper to plate to finger to tapping rod.

OPERATION:
The drawing of the nut is checked first.
 Hopper settings are adjusted as per flange nut
size.
The tap is welded to tap rod.
Insert tap rod in tap guide bush.
Set finger of machine as per size of job.
Set the job plate as per size of job.
Do job rolling settings to guide the nut as per
size.
Load the material in machiine.
Start production after getting first piece
approval.
Sharpen the tap when required.

SELECTION OF RAW MATERIAL:

Now we have seen how the different forging machine
operate. Now let us see how the different raw
materials are selected for a particular product.
The bolts, screws of the specified property class
should meet all the mechanical and physical
properties which are specified in the standard tables.
Apart from the mechanical properties each of the
material should have the required chemical
composition as well.
Thus by knowing the required hardness, tensile
strength and chemical composition the raw material
of particular grade and property class is chosen.

DIFFERENT DRAWINGS:
Drawing plays an important factor in the accurate
manufacturing of bolts and nuts. Drawings are 2-
dimensional sketches of the top and front view of the
required output with all the necessary information
like surface finish, dimensional and geometric
tolerance, etc.
The different types of drawings are:

Product Drawing: It represents the 2-d sketch of

the final product with the necessary dimension and
tolerances of the front and top view. It also
represents the material used, the part number and
all the necessary information pertaining to the plant.

Forging Drawing: It represents the different stages

in the forging operation in the form of drawing with
the given dimension and appropriate dimensional
and geometric tolerance.

Tool Drawing: Similar to the forging operation tool

drawing also represents the different tool making
procedure in form of mechanical drawings helping in
tool assembly of the forging machines.

NEW PRODUCT DEVELOPMENT

PROCESS

CONCLUSION:
REFERENCES:
1 Nut Forming Machine Manual
2 Bolt Forming Machine Manual
3 Nut Tapping Machine Manual
4 Bolt Rolling Machine Manual
5 www.wikipedia.org

GLOSSARY: