REPORT ON CONVERSION OF INVESTMENT CASTING COMPONENTS TO FORGING

Submitted ToVINEET MAHAJAN Asst. Manager A.D.D

Submitted ByANANT SINGH MECHANICAL Engg. IIMT, Meerut

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ACKNOWLEDGEMENT This training would not have been useful to me without the utmost support and guidance from many people in the, Auxiliary and Development Department of TATA MOTORS LTD. Firstly, I would like to thank Mr. NAVNIT MALHOTRA (AGM) who helped me throughout the training by sharing his knowledge and lots of experience he possesses, weathered over the years in the automotive industry, it was indeed very precious working under him. Also, I appreciate the guidance provided to me by Mr. VINEET MAHAJAN (Asst. Manager, ADD) who with his inspiring & innovative ideas, in a way, showed me the path to enlighten myself in order to increase the capacity to do work. I am grateful to Mr. Brijlal Arora (HR- Training cordinator) for letting me go through the training, & making it altogether a diverse experience. Last but not the least, I would like to thank the entire group of TATA MOTORS LTD. -Pantnagar Plant, who helped me in every sphere they could, and didnt even let me gauge how long or short this period can be.

INDEX S. No. Page No.

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1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18. 19. 20. 21. 22. 23. 24.

Acknowledgement World and Automobile India and Automobile Tata Group of Companies Tata Motors Ltd. Area of Business Joint ventures, Subsidiaries and Associates Research and Development Location Tata motors Hierarchy Tata Motors Pantnagar S.I.P Introduction Investment Cating Forging Types of Forging Investment Casting conversion and comparison. Investment Casting Vs. Forging Scope. Engg. Process. Control Plan F.M.E.A P.P.A.P Learning at TATA-MOTORS. Bibliography.

2 4 5 7 8 9 9 10 11 12 14 15 16 17 18 20 27 27 28 28 29 35 39 39 40

1) World & Automobile

During the 1670s, Father Ferdinand Verbiest (Flemish Jesuit missionary, China) designed the first ever self-propelled vehicle many claim this as the world's first automobile but lack of evidence that it was actually built, in spite of its small size it could only operate for 12-15 minutes before running out of steam, and its tremendous weight and poor balance made it very difficult to steer

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The first car was built by Joseph Cugnot in 1769. It was powered by a steam engine and was very slow.

Notable Personalities of Past : 1 cylinder IC engine 4 cylinder IC engine 1st 4-wheel automobile & v-slanted engine Automobile powered by IC engine Over 15 million Model Ts by 1927 Hybrid cars 1st hybrid commercial truck J.J. tienne Lenoir N. August Otto Gottlieb Daimler (1886)

Karl Benz Henry Ford Since the 1900s. in 1910

2) India & Automobile Automobile: o Public Transport o Personal Transport o War-fare o Law and order o Trade o Emergency Services o Public Hygiene o Sea Transport o Aero planes

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Indian Automobile has 12 % share in Indian economy AUTOMOBILE COMPANIES making the Dream Machines in India:

The forecast of various type of 4-wheelers production in India:

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GRAPH 2 Passenger Vehicles

GRAPH 3 Commercial Vehicles

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3) TATA GROUP OF COMPANIES Tata Group, an Indian multinational conglomerate company, headquartered in the Bombay House in Mumbai, India, in terms of market capitalization and revenues, it is the largest private corporate group in India. The Tata Group comprises 114 companies and subsidiaries in eight business sectors, 27 of which are publicly listed. 65.8% of the ownership of Tata Group is held in charitable trusts. The group takes the name of its founder, Jamsedji Tata, a member of whose family has almost invariably been the chairman of the group. The current chairman of the Tata group is Ratan Tata. The Tata Group has operations in more than 80 countries across six continents and its companies export products and services to 80 nations. TATA Group's 114 companies are held by its main Company Tata Sons. The 2009 annual survey included 600 global companies by the Reputation Institute ranked Tata Group as the 11th most reputable company in the world. TATA GROUP of COMPANIES Information technologies CMC Computational Research Labs Nelito Systems Tata Advanced Systems Tata Business Support Services T ata Consultancy Services Tata Elxsi Tata Interactive Systems Tata Technologies Comunication Tata Communicatio n Tata Teleservices Tata sky Tata Net Nelco

Automotive Hispano Carrocera Jaguar Land Rover Tata AutoComp Systems Tata Cummins Tata Daewoo Commercial Vehicle Company Tata Motors Tata Motors European Technical Centre

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Telco Construction Equipments Engineering TAL Manufacturing Solutions Tata Consulting Engineers Tata Projects TRF Voltas

NatSteel Holdings Tata BlueScope Steel Tata Metaliks Tata Sponge Iron Tata Steel Tata Steel KZN Tata Steel Processing and Distribution Tayo Rolls The Tinplate Company of India TM International Logistics

Metals Hooghly Met Coke & Power JAMIPOL Jamshedpur Utilities and Services Mjunction services Energy North Delhi Power Powerliks Transmission Consumer Product Casa Decor Infiniti Retail Landmark Tata Ceramics Chemicals Advinus Therapeutics Rallis India Tata Chemicals Tata Chemicals Europe Tata Chemicals Magadi

Tata BP Solar Tata Petrodyne Tata Power & Tata Power Trading Tata Global Beverages Titan Industries Trent Westland Tata Chemicals North America Tata Pigments

Other services Drive India Enterprise Solution Tata Industrial Services Tata Quality Management Services

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Tata Services

Tata Strategic Management

4) TATA MOTORS Tata Motors Limited is a multinational automotive corporation. A part of the Tata Group, it was formerly known as TELCO (TATA Engineering and Locomotive Company). Established in 1945 by J.R.D.Tata, Tata Motors' presence indeed cuts across the length and breadth of India. Tata Motors is India's largest automobile company, with consolidated revenues of Rs. 1, 23,133 crores ($ 27 billion) in 2010-11. Through subsidiaries and associate companies, Tata Motors has operations in the UK, South Korea, Thailand and Spain. Among them is Jaguar Land Rover, the business comprising the two iconic British brands. It also distributes Fiat cars in India, and has an industrial joint venture with Fiat in India. With over 5.9 million Tata vehicles plying in India, Tata Motors is the country's market leader in commercial vehicles and among the top three in passenger vehicles. It is also the world's 4th largest truck manufacturer and 3rd largest bus manufacturer. Tata cars, buses and trucks are being marketed in several countries in Europe, Africa, the Middle East, South Asia, South East Asia and South America 4a) Areas of business: Tata Motors makes passenger cars, multi-utility vehicles and light, medium and heavy commercial vehicles.

Passenger cars: compact Tata Indica in 1998, the sedan Indigo in 2002 and the station wagon Indigo Marina in 2004. Tata Motors also distributes Fiats cars in India. Utility vehicles: The Tata Sumo was launched in 1994 and the Tata Safari in 1998.

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Commercial vehicles: The commercial vehicle range extends from the light two-tonne truck to heavy dumpers and multi-axled vehicles in the above 40tonne segment. Passenger buses: The Company also manufactures and sells passenger buses, 12-seaters to 60-seaters, in the light, medium and heavy segments.

4b) JOINT VENTURES, SUBSIDIARIES, ASSOCIATES Tata Motors has joint ventures with MARCOPOLO, the Brazilbased maker of bus and coach bodies, and with FIAT-AUTO (to build a commercial vehicle at Fiat's facilities in Crdoba, Argentina). Other associates include: Tata Daewoo Commercial Vehicle Co.: heavy commercial vehicles Tata Motors European Technical Centre: design engineering and development of products. Telco Construction Equipment Company: construction equipment and allied services. Tata Technologies: design services, product lifecycle management and product-centric IT services. Tata Motors (Thailand): Tata Motors (70%) and Thonburi Automotive Assembly Plant Co (30%). Tata Cummins: manufactures high horsepower engines. HV Transmissions and HV Axles: make gearboxes and axles for commercial vehicles. TAL Manufacturing Solutions: provides factory automation solutions and provides machine tools. Hispano Carrocera: Spanish bus manufacturing company. Concorde Motors: retailing Tata Motors range of passenger vehicles Tata Motors Finance: the business of financing customers and channel partners of Tata Motors 4c) Research & Development

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The companys Engineering Research Centre (ERC), in Pune (which has 1400 scientists and engineers), Tata Daewoo Commercial Vehicle Company Hispano Carrocera at Gunsan in Korea and Zaragoza in Spain. These three facilities together enable the company to share and access knowledge and technology for designing and developing world-class products which are environmentfriendly technologies in emissions and alternative fuels.

It was Tata Motors, which developed the first indigenously developed Light Commercial Vehicle, Indias first Sports Utility Vehicle Tata Indica, Indias first fully indigenous passenger car (Indias largest selling car) Tata Ace, Indias first mini-truck. The ERC in Pune, among whose facilities are Indias only certified crash-test facility and hemi-anechoic chamber for testing of noise and vibration has received several awards from the Government of India. Some of the more prominent amongst them are: National Award for Research and Development Efforts in Industry in the Mechanical Engineering Industries sector in 1999, National Award for Successful Commercialization of Indigenous Technology by an Industrial Concern in 2000 CSIR Diamond Jubilee Technology Award in 2004. Adopting the principle of Kaizen or continuous learning, versatile yet simple 5S approach to process improvement which helps to optimize various operations of the company

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and conserve precious resources is the way of life at Tata Motors. The company introduced emission-friendly engines in its products in India even before such norms were made statutory. It ensures that its products are environmentally sound by reducing hazardous materials in vehicle components, developing extended life lubricants, fluids and using ozone-friendly refrigerants.

4d) Location Tata Motors' plants are located at o Jamshedpur (eastern India), o Pune and Sanand (western India), o Lucknow and Pantnagar (northern India). o Tata Motors and Fiat have a common manufacturing facility at Ranjangaon, near Pune.

being marketed in several Europe, countries South East Asia, Malaysia, Ukraine, assembly operations Senegal..

Africa, South Asia and Kenya, Russia,

Middle East, Australia Bangladesh, Spain and

4e) TATA Motors Hierarchy Board of Directors

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 Mr. Ratan N. Tata (Chairman) Mr. Ravi Kant Mr. Nusli N. Wadia Mr. S. M. Palia Dr. R. A. Mashelkar Mr. Nasser Munjee Senior Management Mr. Carl-Peter Forster Mr. P. M. Telang Mr. C. Ramakrishnan Mr. Ravi Pisharody Dr. Tim Leverton Mr. S. B. Borwankar Mr. Prabir Jha Mr. R. Ramakrishnan Mr. Girish Wagh Mr. R. T. Wasan Mr. Johnny Oommen Mr. H. K. Sethna

Mr. Subodh Bhargava Mr. V. K. Jairath Mr. Ranendra Sen Dr. Ralf Speth Mr. Carl-Peter Forster Mr. P. M. Telang

Managing Director & Group CEO Managing Director - India Operations Chief Financial Officer President (CVBU) Head (Advanced and Product Engineering) Senior Vice President (Mfg Operations-CVBU) Senior Vice President (Human Resources) Vice - President (Commercial - PCBU) Head (Passenger Car Operations - PCBU) Head (International Business - CVBU) Head (International Business - PCBU) Company Secretary

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FIG. 2: Fuel type- Diesel, Gasoline and CNG

4f) TATA MOTORS (Small Car Division) Pantnagar

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This plant came into existence in 2007. TATA MOTORS LTD. Pant Nagar has four shops for manufacturing of vehicles.

DESCRIPTION OF SHOPS

ASSEMBLY SHOP Also known as TCF Shop(TRIM CHASSIS FITTING). In this shop all the assembly works like Engine, Suspension, Tyres, Lights, Dashboard etc. fitting is carried out.

WELD SHOP Also known as BIW Shop(BODY IN WHITE) . Here the different parts are welded together and the whole structure of the car is built.

POWER TRAIN SHOP o This shop is divided into Power Train and Engine shop. Here various operations related to Engine, Gear Trains etc. are performed.

PAINT SHOP The TAIKISHA paint shop is the beauty parlors of the car plant. This shop paints the car in various shades. It takes 18 steps spread over less than 10 hours to accomplish the task.

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GEAR 15 CKD(COMPLETE KNOCK DOWN) ASSEMBLY BIW-1C BIW-1B BIW-1A

TATA MOTORS SUMMER INTERNSHIP PROJECT (SIP) ON CONVERSION OF INVESTMENT CASTING COMPONENTS TO FORGING

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INTRODUCTION

INPUTS
MAN MATERIAL MACHINE/TOOLING METHOD ENVRIONMENT

PROCESS

OUTPUT

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Investment Castings
Featuring unlimited alloy choices, investment castings are the most versatile metal forming methods available. Designers are not limited to any particular alloy, as the investment casting process allows for easy alloy substitution using the same tooling. Each alloy has unique mechanical properties, including varying degrees of hardness, corrosion resistance, electrical conductivity, and ductility. Visit each alloy page for real world examples of how Precision Castings of Tennessee is changing the investment casting industry. Stainless Steel Castings

Highest heat resistance

Can meet any surface finish without plating Can be polished to a mirror finish Ultimate in corrosion resistance

Steel Castings

Cost-effective Widest range of mechanical properties Smooth surface finish without grinding

Bronze, Brass & Copper Castings

High fatigue resistance High ductility Non-corrosive Self-lubricating

Tool Steel Castings

Aluminium Castings

Engineered for impact & edge based tools High wear resistance High hardness levels

Stronger than steel pound for pound High heat dispersion capabilities Ideal for weight reduction

Ductile Iron Castings

Cobalt & Nickel Based Castings

Impressive mechanical properties Fatigue resistance More cost-effective than steel

Woodworking Metal Castings

High alloy steels and exotics Highest corrosion resistance

High-impact toughness Design improvement opportunities Razor-sharp edges

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FORGING
Forging is a manufacturing process involving the shaping of metal using localized compressive forces. Forging is often classified according to the temperature at which it is performed: "cold", "warm", or "hot" forging. Forged parts can range in weight from less than a kilogram to 580 metric tons.Forged parts usually require further processing to achieve a finished part.

HISTORY: Forging is one of the oldest known metalworking processes.Traditionally, forging was performed by a smith using hammer and anvil, and though the use of water power in the production and working of iron dates to the 12th century, the hammer and anvil are

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not obsolete. The smithy or forge has evolved over centuries to become a facility with engineered processes, production equipment, tooling, raw materials and products to meet the demands of modern industry. In modern times, industrial forging is done either with presses or with hammers powered by compressed air, electricity, hydraulics or steam. These hammers may have reciprocating weights in the thousands of pounds. Smaller power hammers, 500 lb (230 kg) or less reciprocating weight, and hydraulic presses are common in art smithies as well. Some steam hammers remain in use, but they became obsolete with the availability of the other more convenient, power sources.

ADVANTAGES and DISADVANTAGES: Forging can produce a piece that is stronger than an equivalent cast or machined part. As the metal is shaped during the forging process, its internal grain deforms to follow the general shape of the part. As a result, the grain is continuous throughout the part, giving rise to a piece with improved strength characteristics. Some metals may be forged cold, but iron and steel are almost always hot forged. Hot forging prevents the work hardening that would result from cold forging, which would increase the difficulty of performing secondary machining operations on the piece. Also, while work hardening may be desirable in some circumstances, other methods of hardening the piece, such as heat treating, are generally more economical and more controllable. Alloys that are amenable to precipitation hardening, such as most aluminium alloys and titanium, can be hot forged, followed by hardening.[citation needed] Production forging involves significant capital expenditure for machinery, tooling, facilities and personnel. In the case of hot forging, a hightemperature furnace (sometimes referred to as the forge) is required to heat ingots or billets. Owing to the massiveness of large forging hammers and presses and the parts they can produce, as well as the dangers inherent in working with hot metal, a special building is frequently required to house the operation. In the case of drop forging operations, provisions must be made to absorb the shock and vibration generated by the hammer. Most forging operations use metal-forming dies, which must be precisely machined and carefully heat-treated to correctly shape the workpiece, as well as to withstand the tremendous forces involved.

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PROCESS: There are many different kinds of forging processes available, however they can be grouped into three main classes.

Drawn out: length increases, cross-section decreases Upset: length decreases, cross-section increases 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.

Temperature: Main articles: Hot working and Cold working All of the following forging processes can be performed at various temperatures, however they are generally classified by whether the metal temperature is above or below the recrystallization temperature. If the temperature is above the material's recrystallization temperature it is deemed hot forging; if the temperature is below the material's recrystallization temperature but above 30% of the recrystallization temperature (on an absolute scale) it is deemed warm forging; if below 30% of the recrystallization temperature (usually room temperature) then it is deemed cold forging. The main advantage of hot forging is that as the metal is deformed work hardening effects are negated by the recrystallization process. Cold forging typically results in work hardening of the piece. TYPES: Drop forging: Drop forging is a forging process where a hammer is raised up and then "dropped" onto the workpiece to deform it according to the shape of the die. There are two types of drop forging: open-die drop forging and closed-die drop forging. As the names imply, the difference is in the shape of the die, with the former not fully enclosing the workpiece, while the latter does. Open-die drop forging: Open-die forging is also known as smith forging.In open-die forging, a hammer strikes and deforms the workpiece, which is placed on a

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stationary anvil. Open-die forging gets its name from the fact that the dies (the surfaces that are in contact with 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 some have a specially shaped surface for specialized operations. For example, a 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 smithing and custom work. In some cases, open-die forging may be employed to rough-shape ingots to prepare them for subsequent operations. Open-die forging may also orient the grain to increase strength in the required direction. Cogging is successive deformation of a bar along its length using an open-die drop forge. It is commonly used to work a piece of raw material to the proper thickness. Once the proper thickness is achieved the proper width is achieved via edging.[8] Edging is the process of concentrating material using a concave shaped open die. The process is called edging, because it is usually carried out on the ends of the workpiece. Fullering is a similar process that thins out sections of the forging using a convex shaped die. These processes prepare the workpieces for further forging processes.

Impression-die drop forging: Impression-die forging is also called closed-die forging. In impressiondie forging, the 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, forming what is referred to as 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 removed. 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.

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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 an edging, fullering, or bending impression. The following cavities are called blocking cavities, in which the piece is working into a shape that more closely resembles the final product. These stages usually impart the workpiece with 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 instead machine the final features. Impression-die forging has been 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 include additional cost due to a more complex die design and the need for better lubrication and workpiece placement. There are other variations of part formation that integrate impression-die forging. One method incorporates casting a forging preform from liquid metal. The casting is removed after it has solidified, but while still hot. It is then finished in a single cavity die. The flash is trimmed, then the part is quench hardened. Another variation follows the same process as outlined above, except the preform is produced by the spraying deposition of metal droplet into shaped collectors (similar to the Osprey process). Closed-die forging has a high initial cost due to the creation of dies and required design work to make working die cavities. However, it has low recurring costs for each part, thus forgings become more economical with more volume. This is one of the major reasons closed-die forgings are often used in the automotive and tool industry. Another reason forgings are common in these industrial sectors is that forgings generally have about a 20 percent higher strength-to-weight ratio compared to cast or machined parts of the same material. Design of impression-die forgings and tooling: Forging dies are usually made of high-alloy or tool steel. Dies must be impact resistant, wear resistant, maintain strength at high temperatures, and have the ability to withstand cycles of rapid heating and cooling. In order to produce a better, more economical die the following rules should be followed:

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The dies should part along a single, flat plane if at all possible. If not the parting plane should follow the contour of the part. The parting surface should be a plane through the center of the forging and not near an upper or lower edge. Adequate draft should be provided; a good guideline is at least 3 for aluminum and 5 to 7 for steel. Generous fillets and radii should be used. Ribs should be low and wide. The various sections should be balanced to avoid extreme difference in metal flow. Full advantage should be taken of fiber flow lines. Dimensional tolerances should not be closer than necessary.

The dimensional tolerances of a steel part produced using the impression-die forging method are outlined in the table below. The dimensions across the parting plane are affected by the closure of the dies, and are therefore dependent on die wear and the thickness of the final flash. Dimensions that are completely contained within a single die segment or half can be maintained at a significantly greater level of accuracy. Dimensional tolerances for impression-die forgings Mass [kg (lb)] Minus tolerance [mm (in)] Plus tolerance [mm (in)] 0.45 (1) 0.15 (0.006) 0.48 (0.018) 0.91 (2) 0.20 (0.008) 0.61 (0.024) 2.27 (5) 0.25 (0.010) 0.76 (0.030) 4.54 (10) 0.28 (0.011) 0.84 (0.033) 9.07 (20) 0.33 (0.013) 0.99 (0.039) 22.68 (50) 0.48 (0.019) 1.45 (0.057) 45.36 (100) 0.74 (0.029) 2.21 (0.087) A lubricant is used when forging to reduce friction and wear. It is also used as a thermal barrier to restrict heat transfer from the workpiece to the die. Finally, the lubricant acts as a parting compound to prevent the part from sticking in the dies. Press forging: Press forging works by slowly applying a continuous pressure or force, which differs from the near-instantaneous impact of drop-hammer forging. The amount of time the dies are in contact with the workpiece is measured in seconds (as compared to the milliseconds of drop-hammer forges). The press forging operation can be done either cold or hot. The main advantage of press forging, as compared to drop-hammer forging, is its ability to deform the complete workpiece. Drop-hammer forging usually only deforms the surfaces of the workpiece in contact with the hammer and anvil; the interior of the workpiece will stay relatively undeformed. Another advantage to the process includes the

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knowledge of the new part's strain rate. We specifically know what kind of strain can be put on the part, because the compression rate of the press forging operation is controlled. There are a few disadvantages to this process, most stemming from the workpiece being in contact with the dies for such an extended period of time. The operation is a timeconsuming process due to the amount and length of steps. The workpiece will cool faster because the dies are in contact with workpiece; the dies facilitate drastically more heat transfer than the surrounding atmosphere. As the workpiece cools it becomes stronger and less ductile, which may induce cracking if deformation continues. Therefore heated dies are usually used to reduce heat loss, promote surface flow, and enable the production of finer details and closer tolerances. The workpiece may also need to be reheated. When done in high productivity, press forging is more economical than hammer forging. The operation also creates closer tolerances. In hammer forging a lot of the work is absorbed by the machinery, when in press forging, the greater percentage of work is used in the work piece. Another advantage is that the operation can be used to create any size part because there is no limit to the size of the press forging machine. New press forging techniques have been able to create a higher degree of mechanical and orientation integrity. By the constraint of oxidation to the outer layers of the part, reduced levels of microcracking occur in the finished part. Press forging can be used to perform all types of forging, including open-die and impression-die forging. Impression-die press forging usually requires less draft than drop forging and has better dimensional accuracy. Also, press forgings can often be done in one closing of the dies, allowing for easy automation. Upset forging: Upset forging increases the diameter of the workpiece by compressing its length.Based on number of pieces produced this is the most widely used forging process.A few examples of common parts produced using the upset forging process are engine valves, couplings, bolts, screws, and other fasteners. Upset forging is usually done in special high-speed machines called crank presses, but upsetting can also be done in a vertical crank press or a hydraulic press. The machines are usually set up to work in the horizontal plane, to facilitate the quick exchange of workpieces from one station to the next. The initial workpiece is usually wire or rod, but some machines can accept bars up to 25 cm (9.8 in) in diameter and a capacity of over 1000 tons. The standard upsetting machine employs split dies that contain multiple cavities. The dies open enough to allow the workpiece to move from one cavity to the next; the dies then close and the heading tool, or ram, then moves longitudinally against the bar, upsetting it into the cavity. If all of the cavities are utilized on every cycle

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then a finished part will be produced with every cycle, which makes this process advantageous for mass production. These rules must be followed when designing parts to be upset forged:

The length of unsupported metal that can be upset in one blow without injurious buckling should be limited to three times the diameter of the bar. Lengths of stock greater than three times the diameter may be upset successfully provided that the diameter of the upset is not more than 1.5 times the diameter of the stock. In an upset requiring stock length greater than three times the diameter of the stock, and where the diameter of the cavity is not more than 1.5 times the diameter of the stock, the length of unsupported metal beyond the face of the die must not exceed the diameter of the bar.

Automatic hot forging: The automatic hot forging process involves feeding mill-length steel bars (typically 7 m (23 ft) long) into one end of the machine at room temperature and hot forged products emerge from the other end. This all occurs rapidly; small parts can be made at a rate of 180 parts per minute (ppm) and larger can be made at a rate of 90 ppm. The parts can be solid or hollow, round or symmetrical, up to 6 kg (13 lb), and up to 18 cm (7.1 in) in diameter. The main advantages to this process are its high output rate and ability to accept low-cost materials. Little labor is required to operate the machinery. There is no flash produced so material savings are between 20 and 30% over conventional forging. The final product is a consistent 1,050 C (1,920 F) so air cooling will result in a part that is still easily machinable (the advantage being the lack of annealing required after forging). Tolerances are usually 0.3 mm (0.012 in), surfaces are clean, and draft angles are 0.5 to 1. Tool life is nearly double that of conventional forging because contact times are on the order of 0.06 second. The downside is that this process is only feasible on smaller symmetric parts and cost; the initial investment can be over $10 million, so large quantities are required to justify this process. The process starts by heating the bar to 1,200 to 1,300 C (2,192 to 2,372 F) in less than 60 seconds using high-power induction coils. It is then descaled with rollers, sheared into blanks, and transferred through several successive forming stages, during which it is upset, preformed, final forged, and pierced (if necessary). This process can also be coupled with high-speed cold-forming operations. Generally, the cold forming operation will do the finishing stage so that the advantages of cold-working can be obtained, while maintaining the high speed of automatic hot forging.

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Examples of parts made by this process are: wheel hub unit bearings, transmission gears, tapered roller bearing races, stainless steel coupling flanges, and neck rings for LP gas cylinders.Manual transmission gears are an example of automatic hot forging used in conjunction with cold working. Roll forging: Roll forging is a process where round or flat bar stock is reduced in thickness and increased in length. Roll forging is performed using two cylindrical or semi-cylindrical rolls, each containing one or more shaped grooves. A heated bar is inserted into the rolls and when it hits a stop the rolls rotate and the bar is progressively shaped as it is rolled through the machine. The piece is then transferred to the next set of grooves or turned around and reinserted into the same grooves. This continues until the desired shape and size is achieved. The advantage of this process is there is no flash and it imparts a favorable grain structure into the workpiece. Examples of products produced using this method include axles, tapered levers and leaf springs. Net-shape and near-net-shape forging. Near-net-shape: This process is also known as precision forging. It was developed to minimize cost and waste associated with post-forging operations. Therefore, the final product from a precision forging needs little or no final machining. Cost savings are gained from the use of less material, and thus less scrap, the overall decrease in energy used, and the reduction or elimination of machining. Precision forging also requires less of a draft, 1 to 0. The downside of this process is its cost, therefore it is only implemented if significant cost reduction can be achieved. Cost implications: To achieve a low-cost net shape forging for demanding applications that are subject to a high degree of scrutiny, i.e. non-destructive testing by way of a dye-penetrant inspection technique, it is crucial that basic forging process disciplines be implemented. If the basic disciplines are not met, subsequent material removal operations will likely be necessary to remove material defects found at non-destructive testing inspection. Hence low-cost parts will not be achievable. Example disciplines are: die-lubricant management (Use of uncontaminated and homogeneous mixtures, amount and placement of lubricant). Tight control of die temperatures and surface finish / friction.

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Induction forging: Unlike the above processes, induction forging is based on the type of heating style used. Many of the above processes can be used in conjunction with this heating method. Equipment:

Hydraulic drop-hammer

(a) Material flow of a conventionally forged disc; (b) Material flow of an impactor forged disc The most common type of forging equipment is the hammer and anvil. Principles behind the hammer and anvil are still used today in drophammer equipment. The principle behind the machine is simple: raise the hammer and drop it or propel it into the workpiece, which rests on the anvil. The main variations between drop-hammers are in the way the hammer is powered; the most common being air and steam hammers. Drop-hammers usually operate in a vertical position. The main reason for this is excess energy (energy that isn't used to deform the workpiece) that isn't released as heat or sound needs to be transmitted to the foundation. Moreover, a large machine base is needed to absorb the impacts.

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To overcome some shortcomings of the drop-hammer, the counterblow machine or impactor is used. In a counterblow machine both the hammer and anvil move and the workpiece is held between them. Here List of large forging presses, by force Force Force Ingot size Company Location (tonnes) (tons) (tonnes) 80,000 (88,200) China Erzhong Deyang, China 75,000 (82,690) VSMPO-AVISMA Russia 65,000 (71,660) Aubert & Duval Issoire, France (45,350) 50,000 20 Alcoa, Wyman Gordon USA 40,000 (44,100) Aubert & Duval Pamiers, France 30,000 (33,080) 8 Wyman Gordon Livingston, Scotland excess energy becomes recoil. This allows the machine to work horizontally and have a smaller base. Other advantages include less noise, heat and vibration. It also produces a distinctly different flow pattern. Both of these machines can be used for open-die or closed-die forging. Forging presses: A forging press, often just called a press, is used for press forging. There are two main types: mechanical and hydraulic presses. Mechanical presses function by using cams, cranks and/or toggles to produce a preset (a predetermined force at a certain location in the stroke) and reproducible stroke. Due to the nature of this type of system, different forces are available at different stroke positions. Mechanical presses are faster than their hydraulic counterparts (up to 50 strokes per minute). Their capacities range from 3 to 160 MN (300 to 18,000 short tons-force). Hydraulic presses use fluid pressure and a piston to generate force. The advantages of a hydraulic press over a mechanical press are its flexibility and greater capacity. The disadvantages include a slower, larger, and costlier machine to operate.The roll forging, upsetting, and automatic hot forging processes all use specialized machinery. List of large forging presses, by ingot size Force Ingot size Company Location (tonnes) (tonnes) 16,000 600 China National Erzhong Group Deyang, China 14,000 600 Japan Steel Works Japan 15,000 580 China First Heavy Industries Group Heilongjiang, China 13,000 Doosan South Korea

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Investment Casting Conversion & Comparison Saving money, one piece at a time Almost any metal part can be converted to an investment casting. Conversions generally allow for weight reduction opportunities, reduced machining, elimination of draft angles, and increased design flexibility. Castings can be converted into any alloy, allowing for virtually unlimited mechanical properties. Candidates for casting conversion include metal parts that are otherwise difficult or impossible to machine, castings with highly complex internal geometries, and expensive alloy types that produce extensive waste using other manufacturing methods. Depending on part complexity and desired production rate, investment casting is not always the best option. The following comparison guide can help you determine if investment casting conversion is right for you. Investment Casting vs. Forging

Investment casting surface finishes eliminate forging parting lines and pitting Investment castings offer uniform internal stresses Forging process causes directional stresses

Forging tooling is generally more expensive Scope Conversion of investment casting to forging:

Sl. No.

Features

Investment Casting

Forging

1.

Vendors

Limited

Easily Available

2.

Availability

Out of state

In state

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3.

Transportation

Complex

Easy

4.

Excise Duty

Apprx. 12.36%

NIL

ENGINEERING PROCESS: This process is processed by the particular vendors of Tata Motors Ltd. like SANSERA ENGINEERING BAJAJ MOTORS

This process involves the following procedure:

FORGING DRAWING

APL- FORGING DRAWING APPROVAL

DIE MANUFACTURE

ENDURANCE TEST
Not OK

FORGING SAMPLE

FORGING

OK

KOK

PLAN DROPPED

PROCESS APPROVED

TO PLANT

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Control Plan: What is a Control Plan ? A summary of the system for controlling variation of product characteristics. process characteristics. Contract between supplier and customer. Summarizes the entire control strategy.

Objective: To ensure that a written plan for controlling all parts & processes is documented Control Plan - An important phase in Quality Planning Process Control Plan should include All Operations listed on the process flow chart. Machine Jig or Tooling. Product and Process Characteristics. Designated Special Characteristics. Specifications or Tolerances. Gauging or Evaluation Techniques. Sample Size and Frequency. Control Methods. Reaction Instructions at each stage of production .

Information should be consistent with other documents such as DFMEA, Process Flow, PFMEA

Control Plan can be grouped by commonality of Parts.

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Assemblies. Features. Design. Processes. Similar routing. Similar level of complexity .

Control Plan is maintained and used throughout the product life cycle Stages of Control plan Prototype Control Plan Pre-Launch Control Plan. Production Control Plan.

Header Information: Prototype : Developed for prototypes where majority of characteristics are 100 % inspected or tested. Includes a description of measurement/tests that occur during prototype builds. Use production process whenever possible.

Pre-launch or Pilot :
Description of measurements/tests before full production. Most pre-launch should be under typical production condition. Production : Comprehension documentation. Change in Size & Frequency. Encompasses high volume production .

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 Operation Number :
Usually referenced from the Process Flow Chart. If multiple part number exist (assembly), list the individual part numbers and their processes accordingly.

Process Name / Operation Description : All steps in the manufacturing are described in Process Flow Diagram. Identify the name that best describes the activity being addressed e.g. Drilling, Milling, Hobbing, Torque.

Machine, Device, Jigs & Tool Description :

Mention Machine No., Fixture / Jig No. & Tool No. that will be used during actual process.

Characteristics
A distinguishing feature, dimension or property of a process or its output (product) on which data (variable or attribute) can be collected. Use visual aid where applicable.

Number : A cross reference from all applicable documents Blue Prints, FMEAs etc.

Product Characteristics
Features or properties of a product that are described on drawings or primary engineering information.

Process Characteristics:
Process variables that have a cause and effect relationship with identified Product Characteristics. Can be measure only at the time it occurs. Team to identify these for which variation must be controlled to minimise product variation.

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 There could be more than one process characteristics for each characteristics.

Special Characteristics Classification For identified Special characteristics through DFMEA & PFMEA to be put. Appropriate symbols or Identification to be put e.g. <CC> or <SC> For others characteristics to be left blank

Methods: A systematic plan using procedures and other tools to control a process

Product/Process Specification/Tolerance This include actual Product or Process Specification If Speed, Feed are process characteristics, CNC Programme No. reference can also be given. Evaluation Methods / Measurement Technique Systems required to measure product and process characteristics This could include gauges, fixtures, tools and or test equipment required to measure Analysis of linearity, reproducibility, repeatability, stability and accuracy of the measurement system to be done, A reasonable Gauge R & R must be attained The acceptance criteria for GRR is 10 %

Sample Size/Frequency Sampling Guideline: Use rational sampling plans Sample should separate special causes from common causes Based on a unit of production( e.g. parts, kg etc)

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 Event Driven ( at start of the shift, tool change etc.) Control Method : A brief description of how the operation would be controlled Should be based on effective analysis of the process Is determined by the type of process that exists Types : SPC, inspection, sampling, mistake proofing If elaborate control procedure are used, Reference of the procedure number Method of control to be Continually evaluated for effectiveness of process control Typical Entries in Control Method Table: Quality Check Sheets or Inspection Sheets Setup Approval, Operation Instructions etc. PM Check Sheet Process Parameter Logs Tool Change Logs Variable / Attribute Control Charts These controls are generally used for all product characteristics regard less of importance ranking Developing Control Methods For process control to be effective, a basic understanding of Process Management is essential Team should analyse sources of variation in the process identify dominant factor to suitably decide controls Reaction Plan:

It specifies what to do when: a failure occurs the process goes out of control

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 the process improves The typical reactions are: contain investigate record (good and bad incidences) Reaction Plans are mechanisms for continuous improvement and standardisation This column will typically contain reference to a detailed document As a part of QS 9000 requirements, Control of Nonconforming Product require, Identification, documentation, evaluation and segregation and disposition of nonconforming product Some more Details: In support of control plan, process monitoring instructions should be defined Control Plan does not replace the information contained in detailed operator instructions Sketches to be attached for better illustration Control Plan is updated as measurement systems & control methods are evaluated & improved Assessment of Control Plan for Quality of Event A checklist for assessment of Control Plan is used Prototype, Pre-launch, Production

The checklist basically mentions the activities expected to be done during the Control Plan. While performing the assessment, assessor(s) should review each point by posing question, has the expectation been met? It should be Rated as per the guideline The minimum Overall Score Expected is 2

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Checklist can be used anytime

Benefits of Control Plan Provides a thorough evaluation of the product & process Focus resources on characteristics that are important to customer Identifies sources of variation in process which cause variation in product characteristics It describes all actions to assure process would be state of control.

Control Plan Provides a structured approach for the design, selection and implementation of value-added control methods for the total system. FMEA Where does FMEA come from? Developed by the Aerospace industry in the 1960s.

Spread to the Automotive industry. Now used extensively across all industry sectors.

Different Types of FMEA Design

An analytical technique used primarily by Design.

Responsible Engineer/Team as a means to assure potential failure modes, causes and effects have beenaddressed for design related characteristics. Process An analytical technique used primarily by a Manufacturing.

Engineer/Team as a means to assure potential Failure modes. causes and effects have been addressed for process related characteristics. Our Focus is on Process FMEA A structured approach to: Identifying the way in which a process can fail to meet critical

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Customer requirements. Estimating the risk of specific causes with regard to these failures.

Evaluating the current control plan for preventing these failures from occurring. Prioritising the actions that should be taken to improve the process.

STRUCTURE OF FMEA

Component Proving Process

Mistake Proofing Techniques

FMEA
Continuous Improvement Programs

Concept:

plan

To identify ways the product or process can fail and then

to prevent those failures, utilising mistake proofing tools and techniques. Why we use FMEA rather than cure? Increase probability of DETECTION.

Identify biggest contributor to failures and eliminate them. Reduce probability of failure occurring.

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Build quality into the product & process.

When to use FMEA? FMEA is most beneficial as a beforethe-event action.

Design FMEA should be done during initial design of product. Process FMEA should be done during design of manufacturing process.

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P.P.A.P

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Learnings at Tata Motors

Being one of the most technically sound and having few of the costliest technologies among the Asian automobiles, the culture in the Tata Motors is free, motivating and appreciative.

Here the culture of Equality is fully nurtured all the people operator to senior level are given equal respect through all the possible manner like same Canteen facility, same transportation facility, same uniform among various levels.

The lesson of Time is Money & Creativity is thinking up new things Innovation is doing new things. is taught from day 1 to all employees.

The lesson of Appreciate your colleagues work is well taught from senior level manager to all the man-force in TML, Pantnagar.

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10) BIBLOGRAPHY

1. www.google.co.in 2. www.wikipedia.com 3. www.tatamotors.com 4. http://www.acmainfo.com/pdf/Status_Indian_Auto_Industry.pd f (Graphs 2009, 15, 20). 5. http://www.imaginmor.com/automobileindustryindia.html (Pi charts) 6. http://www.tatamotors.com/know-us/milestone.php 7. http://www.tata.com/businesses/sectors/index.aspx? sectid=aZ72PXPwpaI=#Informationsystemsandcommunicatio ns (Tata Group of Companies) 8. http://www.exampleessays.com/viewpaper/17379.htm (1800 1st automobile)

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