Is 3469 Forging Tolerance Pdf Download

OUR MANUFACTURING SET UP:

Main production machinery comprises a 1.5 & 0.75 Ton Belt Drop Hammers with an annual capacity of 1400 Metric Tons forging of carbon and alloy steel, non-ferrous, special metals viz. Titanium & Nickel Base alloys, Stainless steel etc. The supporting machinery consist of 200 Tons and 150 Tons trimming presses, oil fire furnaces or billet heating and heat treatment, bar shearing machine, Shot blasting machine etc.

Indo Metaforge Pvt. Ltd. is an ISO 9001:2008 certified, forging industry. Annual turnover of Rs. 15 crores. in 2021-22. The company is located at D-14, M.I.D.C., Ahmednagar 414111 which has good infrastructure of roads, administrative office, laboratory, telecommunication & regular supply of electricity. Total area of factory is around 4050 Sq. meters.

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The company started its production in March 2006 & is engaged in the manufacture and supply of closed die steel forgings, as a reliable supplier of Quality Forgings to automobiles, tractors and other engineering companies. The components include Shafts, Levers, Yokes, Gears, Flanges, washers and Bearing Bushes etc. Weighing from 1 Kg To 17 Kg as per IS 3469 - 1974 Forging Tolerances.

Main production machinery comprises a 1.5 & 0.75 Ton Belt Drop Hammers with an annual capacity of 2000 Metric Tons forging of carbon and alloy steel, non-ferrous, special metals viz. Nickel Base alloys, Stainless steel etc, The supporting machinery consist of 200 Tons & 150 Tons trimming presses, oil fired furnaces for billet heating & heat treatment, bar shearing machine, Shot blasting machine etc.

At IMF, the raw material required for any forgings are bought only from prime manufacturers in the country viz KSL, SAIL/VISP, ISSAL, SUNFLAG, AARTI STEEL, JSW STEEL etc. These prime manufacturers have been approved as Suppliers, based on our evaluation of their capability and quality systems. We do not compromise on QUALITY. A dedicated, trained and skilled workforce is the backbone of the Quality System.

This data is provided only as a guide and is not to be relied upon for specific design practices. Forging tolerances must be negotiated on a case by case basis, and will vary with design aspects and production techniques.

Rule based DFM analysis for forging is the controlled deformation of metal into a specific shape by compressive forces. The forging process goes back to 8000 B.C. and evolved from the manual art of simple blacksmithing. Then as now, a series of compressive hammer blows performs the shaping or forging of the part. Modern forging uses machine driven impact hammers or presses that deforms the work-piece by controlled pressure.

The forging process is superior to casting in that the parts formed have denser microstructures, more defined grain patterns, and less porosity, making such parts much stronger than a casting. All metals and alloys are forgeable, but each will have a forgeability rating from high to low or poor. The factors involved are the material's composition, crystal structure and mechanical properties all considered within a temperature range. The wider the temperature range, the higher the forgeability rating. Most forging is done on heated work-pieces. Cold forging can occur at room temperatures. The most forgeable materials are aluminum, copper, and magnesium. Lower ratings are applied to the various steels, nickel, and titanium alloys. Hot forging temperatures range from 93C (200F) to 1650C (3000F) for refractory metals.

In open die forging a cylindrical billet is subjected to upsetting between a pair of flat dies or platens. Under frictionless homogeneous deformation, the height of the cylinder is reduced and its diameter is increased. Forging of shafts, disks, rings etc. are performed using the open die forging technique. Square cast ingots are converted into a round shape by this process. Open die forging is classified into three main types; cogging, fullering and edging.

Hot forging is defined as working a metal above its recrystallization temperature. The main advantage of hot forging is that as the metal is deformed the strain-hardening effects are negated by the recrystallization process.

Fillet and edge radii tolerances, Burr tolerances, surface tolerances, tolerances on draft angle surfaces, eccentricity tolerances for deep holes, eccentricity tolerances for pierced holes, tolerances on concentric bosses, tolerances for unforged stock, and tolerances for deformation of sheared ends.

The tolerances for lengths, widths, heights, and thicknesses cover IL only the diligences of dimensions, but also the deviations of form which are: a) Out of round, b) Deviations from cylindricity c) Deviations from parallelism, and d) Other deviations from the specified contour. The deviations arc not to exceed the limits given by the tolerances. In extreme cases they may cover the whole fields of tolerances unless other is agreed to between the supplier and purchaser. Where restrictions deviations of form have been agreed upon, this shall be noted on the drawing.

In order to assist the forging supplier to utilize his experience to the best effect, both in designing the dies and tools and in establishing forging inspection procedures, rt is in the purchaser's interest to supply the following

In instances where the purchaser wishes to prepare his own fully dimensioned forging drawing, it is no less necessary that the drawing of the finished machined component and the other information referred to above should be made available to the supplier.

It is imperative to note that, with the exception concerning draft angle surfaces the tolerances indicated in this standard shall be applied only to those dimensions specifically indicated on the agreed forging drawing.

Tolerances for dimensions not shown on the forging drawing may not be taken from the standard but may be determined, if required, only by calculation based on the dimensions and tolerances which are already shown on the agreed forging drawing.

Any tolerances which are only applicable to specific dimensions shall be indicated on the drawing against the particular dimensions concerned. Ejector mark tolerances and burr tolerances should be shown on the forging drawing against the specific locations. Any special tolerances agreed between the purchaser and the supplier shall be indicated clearly on the forging drawing and shall, wherever possible be entered against the specific dimensions concerned.

The drawing of the forged part which has been accepted by the purchaser is the valid document for inspection of the forged part. This drawing is also the only valid document for tolerances on parts of the forging remaining unmachined

There are many different kinds of forging processes available, however they can be grouped into three main classes: 1. Drawn out: length increases, cross-section decreases 2. Upset: Length decreases, cross-section increases 3. Squeezed in closed compression dies: produces multidirectional flow. Common forging processes include: roll forging, swaging, cogging, open-die forging, impression-die forging, press forging, automatic hot forging and upsetting.

Open-die forging is also known as smith forging. In open-die forging a hammer comes down and deforms the workpieces, which is placed on a stationary anvil. Open-die forging gets its name from the fact that the dies (the working surfaces of the forge that contract the workpiece) do not enclose the workpiece, allowing it to flow except where contacted by the dies. Therefore, the operator needs to orient and position the workpiece to get the desired shape. The dies are usually flat in shape but may have a specially shaped surface for specialized operations; for instance the die may have a round, concave, or convex surface or be a tool to form holes or be a cut-off tool. Open-die forging lends itself to short runs and is appropriate for art smiting and custom work. Other times open-die forging is used to rough shape ingots to prepare it for further operations. This can also orient the grains to increase strength in the required direction.

Impression-die forging is also called closed-die forging. In impression-die work metal is placed in a die resembling a mold, which is attached to the anvil. Usually the hammer die is shaped as well. The hammer is then dropped on the workpiece, causing the metal to flow and fill the die cavities. The hammer is generally in contact with the workpiece on the scale of milliseconds. Depending on the size and complexity of the part the hammer may be dropped multiple times in quick succession. Excess metal is squeezed out of the die cavities; this is called flash. The flash cools more rapidly than the rest of the material; this cool metal is stronger than the metal in the die so it helps prevent more flash from forming. This also forces the metal to completely fill the die cavity. After forging the flash is trimmed off.

In commercial impression-die forging the workpiece is usually moved through a series of cavities in a die to get from an ingot to the final form. The first impression is used to distribute the metal into the rough shape in accordance to the needs of later cavities; this impression is called edging, fullering, or bending impression. The following cavities are called blocking cavities in which the workpiece is working into a shape that more and more resembles the final product. These stages usually impart the workpiece will generous bends and large fillets. The final shape is forged in a final or finisher impression cavity. If there is only a short run of parts to be done it may be more economical for the die to lack a final impression cavity and rather machine the final features.

Impression-die forging has been further improved in recent years through increased automation which includes induction heating, mechanical feeding, positioning and manipulation, and the direct heat treatment of parts after forging.

One variation of impression-die forging is called flashless forging, or true closed-die forging. In this type of forging the die cavities are completely closed, which keeps the workpiece from forming flash. The major advantage to this process is that less metal is lost to flash. Flash can account for 20 to 45% of the starting material. The disadvantages of this process included: additional cost due to a more complex die design, the need for better lubrication, and better workpiece placement. 17dc91bb1f