9 III March 2021

https://doi.org/10.22214/ijraset.2021.33162
 International Journal for Research in Applied Science & Engineering Technology (IJRASET)
ISSN: 2321-9653; IC Value: 45.98; SJ Impact Factor: 7.429
Volume 9 Issue III Mar 2021- Available at www.ijraset.com

Review on Forging Defects in Brass Components

Harish Venugopal1, Infant Joel Sahayaraj2, Raghuraman Srinivasan3, VenkatramanRamamoorthi4, Sivachidambaram
Pichumani5
1, 2
Under Graduate students, 3, 4Professor, 5Research Scholar, School of Mechanical Engineering, SASTRA Deemed University,
Thanjavur – 613401, Tamil Nadu, India.

Abstract: Forging process is used to as the primary process to achieve near net shape by design the complex forging products but
complex forging process having forging deformities can be isolated into six categories as folds, shear defects, cracks, surface
defects, form defects and structural defects emerging because of poor ingot, incorrect heating, improper or incorrect forging
conditions, wrong forging strategies and imperfections coming about because of uneven cooling of the stock subsequent to
forging. Since defects causes high rejection rates, it is essential to move any procedure toward wiping out all imperfections as a
major aspect of a viable consistent change program. A decent quality program starts with a state of mind of influencing it to
right the first run through. Forging forms are no special case to this. Financially, and also from a quality point of view, it is
smarter to understand and control the procedure in order to evade defects as opposed to scrapping the defective parts amid final
inspection. During this research work from the forging shop floor the various defects are observed in the Brass material B16-
C36000 forged components and its type of defects and its causes and effect analysis with remedial measures are discussed during
this study.
Keywords: Forging defects, Cause & Effect Analysis, Brass ASTM B16-C36000.

I. INTRODUCTION
Among all assembling shapes, forging development has an uncommon place since it produces parts of predominant mechanical
properties with minimum abuse of material. In forging, the starting material has a for the most part direct geometry; this material is
plastically deformed in at least one operations into a consequence of decently complex plan. The target of this paper is to distinguish
and understand the forging defects [1]. Forging defects those are more than once happening are talked about alongside their causes
and remedies [2]. As per the forging procedure based on temperature of work piece (hot, cold, and warm forging) and based on
course of action of dies (open, impression and closed-die forging) is given.
Die outline parameters, die material necessities and choice of appropriate die materials are classified the forging procedure [3].
Forging defects likewise depends forging types of gear (mallet and press). Components for determination of forging machine,
attributes and normal uses of forging are given. At that point the fish-bone graph is utilized to investigate the conceivable reasons
for defects like unfilling, mismatch and scale pits [4] through a meeting to generate new ideas and to decide the causes, which may
has the best impact. At last, it is reasoned that the forging procedure gives preferable quality item over the part delivered by some
other procedures with usage of preventive activities to decrease the dismissal rate.Though forging process gives better quality item
looked at than other assembling forms, there are a few defects that are softly to come if an appropriate care isn't taken in forging
process outline. Defects can be characterized as the blemishes [5] that surpass certain cutoff points. There are numerous flaws that
can be considered as being defects, extending from those traceable to the beginning materials to those caused by one of the forging
forms or by post forging operations [6].

II. MAJOR ADVANTAGES OF FORGING

Enhanced internal quality of the forged component because of compressive deformation. Leads to microstructural grain refinement
and uniform grain structure. Due to compressive load casting porosity is eliminated and separation of macro-segregation in the grain
boundaries. Longitudinal grain structure converted into to fine grain structure and it leads to high strength and toughness. This
enhanced toughness improves fatigue properties. Shined surface and controlled surface quality is also be achieved.

III. FORGING DEFECTS

When a forge shop begins to experience defects in their process, they should try to find the root cause of the problem, initiate
corrective action and implement procedures to prevent its recurrence. A brief description of defects and their remedial methods is
given below:

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 International Journal for Research in Applied Science & Engineering Technology (IJRASET)
ISSN: 2321-9653; IC Value: 45.98; SJ Impact Factor: 7.429
Volume 9 Issue III Mar 2021- Available at www.ijraset.com

A. Major Classification of Forging Defects

Fracture-related problems: for instance, inner blasts or chevron cracks, cracks on free surfaces, cracks on die-contacted surfaces.
Metal-flow-related problems: for instance, end grain and poor surface execution; inhomogeneous grain estimate; shear groups and
privately debilitated structures; cold shuts, folds, and laps; flow-through deformities.
Control, materials choice, and utilize problems: for instance, underfill, part distortion, and poor dimensional control;
Instrument over-burden and breakage; intemperate device wear; high initial venture because of equipment cost; poor material utilize
and high scrap misfortune

B. Sub Classification of Forging Defects

Forging Description Causes Remedies

Defect
Incomplete Insufficient Metal Flow Use of light rapid hammer Use forging press for
forging blows full penetration.
penetration

Surface Cracks appear on Excessive working on surface Increase the work

cracking surface. Too low temperature temperature
Crack at the Crack in flash region Very thin flash Increase flash
flash thickness
Cold shut Small cracks occur at Sharp corner (less fillet), Increase fillet radius
(Fold) corners of forging. excessive chilling, high on the die.
friction

Unfilled Some section of die Improper design of forging die Proper die design,
Section cavity not completely or using forging techniques, Proper raw material
(Underfilling) filled by the flowing less raw material, poor and Proper heating.
metal. heating.

Die shift Misalignment of forging Misalignment of the die Proper alignment of

(Mismatch) at flash line. halves. die halves by mistake
proofing

Scale Pits Appearance of irregular Improper cleaning of the stock Proper cleaning of
indentation on surface of used for forging. The oxide stock prior to forging.
forging. and scale

Flakes Internal ruptures in Improper cooling of forging. Follow proper cooling

forged component. Rapid cooling causes the practices.
exterior to cool quickly
causing internal fractures.

Improper Molten metal doesn’t Improper die design. Proper die design.
grain flow flow in intended
direction.

Residual Distortion of parts due to Inhomogeneous deformation Slow cooling of

stresses in internal stresses. and improper cooling forging in furnace or
forging (quenching) of forging. under ash cover over a
period of time.

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 International Journal for Research in Applied Science & Engineering Technology (IJRASET)
ISSN: 2321-9653; IC Value: 45.98; SJ Impact Factor: 7.429
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IV. CAUSE AND EFFECT ANALYSIS OF FORGING DEFECT FOR THE BRASS COMPONENT

Figure 1: Cause & Effect analysis for Improper grain flow

Figure 2: Cause & Effect analysis for Internal cracks

Figure 3: Cause & Effect analysis for Underfill

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 International Journal for Research in Applied Science & Engineering Technology (IJRASET)
ISSN: 2321-9653; IC Value: 45.98; SJ Impact Factor: 7.429
Volume 9 Issue III Mar 2021- Available at www.ijraset.com

Figure 4: Cause & Effect analysis for Scale Pits

Figure 5: Cause & Effect analysis for Cold shuts

Figure 6: Cause & Effect analysis for Surface cracks

Figure 7: Cause & Effect analysis for Black spots

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 International Journal for Research in Applied Science & Engineering Technology (IJRASET)
ISSN: 2321-9653; IC Value: 45.98; SJ Impact Factor: 7.429
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V. DEFECTS THAT MAY RESULT FROM POST FORMING PROCESSES PROCESS POSSIBLE DEFECTS
A. Electroplating: Hydrogen embrittlement, galvanic corrosion
B. Heat treatment: Excessive grain growth, burning of grain boundaries, brittle structure, carburization, decarburization, quench
cracks
C. Electrolytic cleaning Pitting
D. Surface hardening, nitriding, carburizing, anodic hard coating
E. Excessive case thickness, microcracks, embrittled material at stress raisers
F. Machining Tool marks, grinding cracks
G. Welding Weld-metal defects, hydrogen-induced cracking, inclusions, improper structure

VI. CONCLUSION
Forging is an experience situated process. Consistently, a lot of know-how and experience has been amassed in this field, to a great
extent by trial-and-error strategies. Forging process produces final products in brief time with almost no scrap. Accordingly there is
sparing in vitality and material. Forgings now and again cost more than parts delivered by different procedures like-casting or
machining, however it gives more dependable parts with better mechanical and metallurgical properties. Since defects causes high
rejection rates, it is essential to move any procedure toward wiping out all imperfections as a major aspect of a viable consistent
change program. A decent quality program starts with a state of mind of influencing it to right the first run through. Forging forms
are no special case to this. Financially, and also from a quality point of view, it is smarter to understand and control the procedure in
order to evade defects as opposed to scrapping the defective parts amid final inspection.

VII. ACKNOWLEDGEMENTS
The authors convey their sincere thanks with gratitude to The Vice Chancellor of SASTRA Deemed to be University, Thanjavur,
India for pursing this research work by providing the facility in the Shanmugha Precision Forging & the School of Mechanical
Engineering, SASTRA Deemed University, Thanjavur – 613401, Tamil Nadu, India.

REFERENCES
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[2] Quality Tools to reduce crankshaft forging defects, A case study. Pankaj Chandna, AruneshChandra , Journal of Industrial and forecast method for interval
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[3] Closed die technologies for hot forging, E. Doege, R. Bohnsack, Journal of Materials Processing Technology, 98 (2000) 165-170.
[4] Temperature characteristics of the billet and die in small batch forging production, S. ShamaSundar, A.G, Marathey, S.K Biswas, Journal of mechanical
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[5] Harish Venugopal, Infant Joel Sahayaraj, VenkatramanRamamoorthi, SivachidambaramPichumani, Raghuraman Srinivasan: Study the Temperature in
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[6] Infant Joel Sahayaraj, Harish Venugopal, VenkatramanRamamoorthi, SivachidambaramPichumani, Raghuraman Srinivasan: Categorizing the forging defects
in the forged Brass component material of ASTM B16-C36000; Journal of Advanced Research in Dynamical and Control Systems, 10/2017; Special Issue
(14):345-352.

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