Chapter 1

R.B GROUP

The RB Group of Companies offers excellence in forging, machining, gear cutting and assemblies.
Formed in 1993, the RB Group has grown steadily, initially within India and became International
in 2015 with the acquisition of Shakespeare Forgings Limited in the U.K. The RB Group offers
experience, expertise and execution in forged products offering a one-stop shop for forged
engineered parts, forged gears, machined forgings and assemblies.

The forging, machining and gear cutting plants are based in and around Chandigarh and North of
Delhi. Shakespeare Forgings is based in Cradley Heath, W. Midlands, U.K. and acts both as a
manufacturing base, finished engineering parts from its sister companies in India and as a
warehousing and logistics facility for the groups sales in Europe. The RB group supplies a wide
range of high integrity, safety critical steel parts to a variety of key market sectors including
automotive, petrochemical , rail and tractor manufacture.

1.1 Group In a Glance

R B Forgings Pvt Ltd

R B Forgings Pvt Ltd Unit II

R B Gears Pvt Ltd

Shakespeare Forgings Ltd (UK)

R B Hydrotech Pvt Ltd

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 Fig.1.1 R.B GROUP
1. 2 R.B FORGINGS:

RB Forgings was founded in 1996 and , through a strategic programme of internal investment, has
grown steadily to become a major supplier of high integrity, safety critical parts to many sectors
both within India and internationally.
Export markets include 1st tier automotive companies within U.K., Germany, Italy and N.
America. The forge is capable of producing parts from 0.25kg 35kg and is capable of high
volume production.
CERTIFICATION: The forge is ISO 9002, ISO 9001:2000 and IATF 16949 certified.

Fig1.2 R.B FORGINGS

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1.3 Quality Control & Assurance:

Fig1.3 QUALITY CONTROL & ASSURANCE

R.B. Forgings has a fully integrated Quality Assurance System with inhouse standards room and
a metallurgical Laboratory. Forging is practiced with PPAP and TQM techniques. The laboratory is
well equipped and is able to satisfy the most demanding customer specifications.

The laboratory houses a spectrometer for chemical analysis as well as for normal metallurgical
facilities expected of a quality forge, i.e magna flux crack detecting, hardness testers and
microscopy. Our qualified personnel ensures that the written procedures from the Quality
Assurance Manual are adhered to throughout the Company.

CHAPTER 2
4
FORGING

2.1. History:

Forging is one of the oldest known metalworking processes. Traditionally, forging was performed
by a smith using hammer and anvil, though introducing water power to the production and working
of iron in the 12th century allowed the use of large trip hammers or power hammers that
exponentially increased the amount and size of iron that could be produced and forged easily. 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.

Fig2.1 BELT DROP HAMMER

2.2 Introduction:

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Forging is the metal working processes, in which the material is deformed to the various required
shape and size. The various parts produced by this processes varies from automotive applications
to the various structural parts in different structures like bridges, etc. After completing the
experiment, the students will be able to:

2.3 Definitions:
(1) Forging press means a mechanically or hydraulically operated press using closed or flat dies.
(2) Forging rolls (reducing rolls) means rolls used as equipment for forging or swaging
operations. Forging rolls are required essentially for reducing short, thick stock sections into
long, slender sections and to perform or reduce cross-sectional areas of billets before the
finished forging operation.
(3) Guide bolt means a bolt which passes through the hammer columns and secures the ram
guides in the pocket.
(4) Hammer means a machine designed to shape forgings by means of impact between dies. The
force of the impact is by gravity or power supplied by steam, air or mechanical means.
(5) Mechanical hammer means a gravity hammer which uses hydraulic or mechanical devices,
such as friction rolls with boards, belts, or ropes to raise the ram and attachments.
(6) Point of operation means the area of a machine, die, or tool where material is actually
worked.
(7) Power shear means a machine equipped with opposing shear blades and which cuts bar
stock.

2.4 THEORY:
2.4.1 FORGING:

Forging is the Oldest of the metal forming operations. It is a Deformation process in which work
is compressed between two dies. The basic metals industries use forging to establish basic shape
of large parts that are subsequently machined to final geometry and size.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.

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Forged parts usually require further processing to achieve a finished part.Most forging operations
are carried out hot, although certain metals may be cold-forged.

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. Other advantages include less noise, heat and vibration. It also
produces a distinctly different flow pattern.The different Products of forging are engine
crankshafts, connecting rods, gears, aircraft structural components, jet engine turbine parts, etc.
Depending upon the application of the forging operation and the required temperature of the
operation, the forging can be grouped into two categories:
i) Hot Forging.
ii) Cold Forging.
The hot-forging is the operation of forging product or components above the
recrystallization temperature for that product. The hot forging results in a reduction in strength
and increase in ductility of work metal, due to refining of the grains of the material. The main
reason behind the use of hot-forging is the capability for substantial plastic deformation of the
metal is far more than as possible with cold working. The other reasons that favours the
application of hot-forging are:

Strength coefficient is substantially less than at room temperature.

Strain hardening exponent is zero (theoretically).
Ductility is significantly increased.

In spite of the various advantages, there are also some disadvantages associated with the hot
forging, as follows:

1. Lower dimensional accuracy.

2. Higher total energy required (due to the thermal energy to heat the workpiece).
3. Work surface oxidation (scale), resulting in a poorer surface finish.
4. Shorter tool life.

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 ii) COLD FORGING:
The cold-forging is the operation of forging product or components at the room temperature or
above the room temperature, but far below than the recrystallization temperature of the product.
The cold forging results in an increase in strength and reduction in ductility of work metal. The
various advantages of cold forging are as follows:

1. Higher dimensional accuracy

2. Lower total energy required.
3. There is no work surface oxidation or scale, resulting in high surface finish.
4. There is a longer tool life.

Disadvantages:
1. It requires larger forces and power than hot forging.
2. The cold forging cannot be used for complex and intricate shape work parts.
3. There is a need of annealing or any other stress relieving process after cold-forging,
in order to relieve stresses in the component, which are induced due to cold-forging.

2.4.2 TYPES OF FORGING:

i) OPEN-DIE FORGING:
Open-die forging is carried out between flat dies or dies of very simple shape. The process is
used formostly large objects or when the number of parts produced is small. Open-die
forging is often used to preform the work piece for closed-die forging. Open die forging
involves the shaping of heated metal parts between a top die attached to a ram and a bottom
die attached to a hammer anvil or press bed. Metal parts are worked above their
recrystallization temperatures-ranging from 1900F to 2400F for steel-and gradually shaped
into the desired configuration through the skill-full hammering or pressing of the work piece

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Although the open die forging process is often associated with larger, simpler-shaped parts such as
bars, blanks, rings, hollows or spindles, in fact it can be considered the ultimate option in
"custom-designed" metal components. High-strength, long-life parts optimized in terms of both
mechanical properties and structural integrity are today produced in sizes that range from a few
pounds to hundreds of tons in weight. In addition, advanced forge shops now offer shapes that
were never before thought capable of being produced by the open die forging process.

FIG2.2 OPEN-DIE FORGING

ii) CLOSED DIE FORGING:

The work piece is deformed between two die halves which carry the impressions of the
desired final shape. The work piece is deformed under high pressure in a closed cavity. The
process provide precision forging with close dimensional tolerance.

Impression or closed die forging confines the metal in dies, open die forging is
distinguished by the fact that the metal is never completely confined or restrained in the
dies. Most open die forgings are produced on flat dies. However, round swaging dies, V-
dies, mandrels, pins and loose tools are also used depending on the desired part
configuration and its size.Closed die forging is expensive than open-die forging.

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 FIG2.3 CLOSED DIE FORGING

iii) IMPRESSION-DIE FORGING:

In impression-die forging, the work piece acquires the shape of the die-cavities or
impression, while being forged between two shaped dies. Also, there are some materials
that flows outwards and forms a flash. The flash plays significant role in the flow of
material in impression-die forging. The thin flash cools rapidly and because of its frictional
resistance, it subjects the material in the die cavity to high pressures, thereby encouraging
the filling of the die cavity. The blank to be forged is prepared by different means, such as,
Cutting or cropping from an extruded or drawn bar stock, Powder metallurgy. Casting,
Preform blank in a prior forging operation.

FIG 2.4 IMPRESSION-DIE FORGING

As shown in the figure, the blank is placed on the lower die and the upper die begins to descend,
the blanks shape gradually changes, followed by the creation of the flash between the die cavities.

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One variation of impression-die forging is called flash less forging, or true closed-die forging. In
this type of forging, the die cavities are completely closed, which keeps the work piece 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 work
piece placement.

iv) UPSET FORGING

Forging of the ring and rod types with all kinds of heads and shoulders, such as bolts, nuts,
washers, collars, pinion gear blanks, etc. can be conveniently produced by the upset forging. The
upset forging increases the diameter of the work piece by compressing its length. Based on
number of pieces produced, this is the most widely used forging process. A example of parts
produced by using the upset forging process are engine valves, couplings, bolts, screws, and other
fasteners.

FIG 2.5 UPSET FORGING

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Upset forging is usually done in special high-speed machines, i.e. 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 horizontal plane, to facilitate quick exchange of work pieces from one station to the next. The
standard upsetting machine employs split dies that contain multiple cavities. The dies open enough
to allow the work piece 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, then a finished part will be produced with every cycle, which
makes this process advantageous for mass production.

The various rules that must be followed when designing parts to be upset forged are as follows:

1. 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.
2. 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.
3. 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 un supported metal beyond the face of the die must not exceed the
diameter of the bar.

v) 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 work piece 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 work
piece. Drop-hammer forging usually only deforms the surfaces of the work piece in contact
with the hammer and anvil; the interior of the work piece will stay relatively un deformed.
Another advantage to the process includes the 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.

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 FIG 2.6 PRESS FORGING

There are a few disadvantages to this process, most stemming from the work piece being in contact
with the dies for such an extended period of time. The operation is a time-consuming process due to
the amount and length of steps. The work piece will cool faster because the dies are in contact with
work piece; the dies facilitate drastically more heat transfer than the surrounding atmosphere. As the
work piece 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 work piece 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. By the constraint of oxidation to the outer layers of the part,

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reduced levels of micro-cracking 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.

2.4.3 FORGING EQUIPMENTS:

The most common type of forging equipment is the hammer and anvil. The choice of forging
equipment depends on a number of factors, including part size and complexity, material, and the
quality of the parts to be produced. Hammers are often preferred for small to medium batches
because of quicker tool.

This forging equipment can be divided into two basic types:

WORK-RESTRICTED MACHINES:
In work-restricted machines the amount of deformation that can be achieved during
each stroke or blow of the machine is limited by the energy or maximum force
available. If the energy or force capacity is less than is required to deform the part,
then more than one stroke or blow is needed. Machines that fall into this category are
hammers, friction screw presses, and hydraulic presses.

HAMMERS:
Hammers are the most common types of machine used. They are often preferred for
small to medium batches because of quicker tool setups and lower overheads. They
are also used for elongated and branch-type forgings because die areas can be
provided for the larger number of preform dies required for such shapes. The various
types of hammers used are as follows:

GRAVITY DROP HAMMERS:

Gravity drop hammers are the oldest type of forging equipment available. The
principle of operation is that the moving die block is raised by a lifting mechanism
and then released, so that it falls onto the fixed die attached to the anvil. The amount
of deformation that can be carried out is determined by the potential energy of the

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 moving die block at its maximum height. This potential energy is converted into
kinetic energy as the die block falls and is then dissipated in deformation of the work
piece. Various lifting mechanisms are used, including frictional means with boards,
band brakes or belts, or a lifting cylinder employing steam, compressed air, or
hydraulic fluid, as shown in figure These machines are available in a range of blow
energies from 0.6kN-m (60kg-m) to 400 kN-m (40,000 kg-m).

FIG 2.7 DIFFERENT TYPES OF DROP HAMMERS

DOUBLE ACTING OR POWER HAMMERS:

These machines are similar to gravity hammers in that a lifting cylinder raises the
moving tup, but power is also applied to the downward-moving tup to increase the
energy capacity. Energy ratings for similar tup weights are considerably more than for
gravity hammers, and the die closing speeds are higher also. Power comes from
double-acting steam, compressed air, or hydraulic cylinders. Double-acting hammers
are manufactured in a range of energy ratings from 3 kN-m (300 kg-m) to 825 kN-m
(82,500 kg-m).

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 VERTICAL COUNTERBLOW HAMMERS:
In these machines two tups with nearly equal masses are driven by double-acting
cylinders toward each other and impact in the center of the machine. More energy is
dissipated in the work piece than in the foundations and subsoil compared to single-
acting hammers. Very high energy capacities are available in the largest machines,
with ranges from 30 kN-m (3 0,000 kg-m) to 2000 kN-m (200,000 kg-m).

HORIZONTAL COUNTERBLOW HAMMERS:

These machines are also called impacters and two rams are actuated by double acting
cylinders.Heated stock is positioned vertically between the dies by an automatic
transfer mechanism. Energy ranges from 4 kN-m (400 kg-m) to 54 kN-m (5400 kg-m)
are typical.

FIG 2.8 COUNTERBLOW HAMMERS

SCREW PRESSES:

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In screw presses, the upper ram and die are connected to a large vertical screw that can be
rotated by a flywheel, so that the ram can move up and down relative to the fixed die in
the bed of the machine. The ram has a limited amount of energy for each stroke, thus
multiple blows are usually employed similar to hammers. Screw presses are available in
ratings from 0.63 MN to 63 MN (63-6300 tons).

FIG 2.9 SCREW PRESS

HYDRAULIC PRESSES:
Hydraulic presses are available in a wide range of sizes up to the largest at 50,000 tons or
more capacity. The moving die is attached to a ram actuated by a large hydraulic cylinder
Various strokes, forces, and closing speeds can be obtained on hydraulic presses. In some
cases hydraulic presses are fitted with auxiliary horizontally moving rams, and these
enable side depressions to be forged into some parts, although this is not done to a great
extent.

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 FIG 2.10 HYDRAULIC PRESS

STROKE RESTRICTED MACHINES:

In stroke-restricted machines the amount of deformation that can be done is fixed by
the stroke of the machine. If sufficient force or energy to carry out the operation is not
available, then the machine will stall and a larger machine should be used. Mechanical
presses fall into this category, as a crank or eccentric determines the amount of ram
movement.

MECHANICAL PRESSES:
Mechanical presses belong to a class of machine tools that encompass a wide range of
different machine types. Primarily, the mechanical press transforms the rotational
force of a motor into a translational force vector that performs the pressing action.
Therefore, the energy in a mechanical press comes from the motor. These types of
presses are generally faster than hydraulic or screw presses, (actually the screw press
may also be classified as a mechanical press). Unlike some presses, in a mechanical
press, the application of force varies in both speed and magnitude throughout the
distance of the stroke. When performing a manufacturing operation using a
mechanical press, the correct range of the stroke is essential.
In mechanical presses, a crank, knuckle joint, scotch yoke, or moving-wedge
mechanism is used to apply a vertical squeezing motion between the upper moving
die and a lower fixed die, as shown in fig.

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 FIG 2.11 ECCENTRIC PRESS AND RACK & PINION PRESS

2.5 FORGING DEFECTS:

The different types of defects, occurring in the forging operations are as follows:
Incomplete die filling.
Die misalignment.
Forging laps.
Incomplete forging penetration- should forge on the press.
Micro structural differences resulting in pronounced property variation.
Hot shortness, due to high sulphur concentration in steel and nickel.
Pitted surface, due to oxide scales occurring at high temperature stick on the dies.
Buckling, in upsetting forging, due to high compressive stress.
Surface cracking, due to temperature differential between surface and center, or
excessive working of the surface at too low temperature.
Micro cracking, due to residual stress.

2.6 Working principle:

The resulting ram impact velocity is around 6 m/s. The ram strokes are constant. Varying die
heights, for example after die change, are automatically compensated. Because of the chosen mass

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ratio, the lower ram moves at a final velocity of only 1.2 to 1.5 m/s. Similar forging conditions exist
as for anvil hammers. The chances of the blank jumping out or shifting is significantly less than
with conventional counter-blow hammers with rams of similar mass. The installation of ejector
systems
within the hammers working space is also facilitated because of the short stroke of the lower ram
and, therefore, also an automation of the hammer. During the reverse stroke, the air cushions
located under the lower ram dampen the impact when the ram reaches its end position, reducing the
forces absorbed by the foundation and allowing the dissipating energy to be captured directly. This
is a further advantage in comparison with counter-blow hammers of conventional design.

2.7 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. Additionally, forgings can target a lower total cost when compared to a
casting or fabrication. When you consider all the costs that are involved in a products lifecycle
from procurement to lead time to rework, then factor in the costs of scrap, downtime and further
quality issues, the long-term benefits of forgings can outweigh the short-term cost-savings that
castings or fabrications might offer.

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.

Production forging involves significant capital expenditure for machinery, tooling, facilities and
personnel. In the case of hot forging, a high-temperature furnace (sometimes referred to as the
forge) is required to heat ingots or billets. Owing to the size of the massive 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,

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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 work piece, as well as to withstand the tremendous forces involved.

2.8 Parts of forging machine:

Fig 2.12 DIFFERENTS PARTS OF FORGING MACHINE

(1) Frame:

Hammers with capacities up to 200 kJ are designed with a so called U-frame. Above this capacity,
the counter-blow hammer design is preferred because of anvil weight and related transport
problems. In the nineteen fifties, LASCO was one of the first hammer manufacturers to design and
produce the U-frame. The relatively short ram stroke of the double-acting drive enabled the mass of
the LASCO U-frame to be distributed ideally, ensuring high rigidity and solid design. All cross-

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sectional variations meet the results of photo elastic analyses. The frame is made of alloyed cast
steel that has been given a
precise, controlled heat treatment. Frame weight and base area have been designed to be mounted
on spring damping elements. Frame weight and ram weight are optimally coordinated.

(2) Drive:
The encapsulated drive system is installed in a cast head adapted to the demanding working
environments in the forge. The head also serves as an oil reservoir and is mounted with vibration
damping onto the uprights. The use of a forged control block combining most of the important
control elements reduces the need for pipe work almost completely. This type of control system
ensures high operational reliability and efficiency. The heart of the hydraulic drive consists of
durable axial piston pumps driven through flexible couplings by special three-phase motors. The
hydraulic fluid is constantly purified by monitored filtration. Constant, optimal fluid temperature is
guaranteed by automatic temperature control, which, in turn ensures consistent performance
unaffected by ambient temperature and operational conditions and prolonged life of the hydraulic
fluid. LASCOs hydraulic drives have proved their operational reliability over a thousand times. In
times of rapidly rising energy costs, this is one more reason to choose a LASCO product.

(3) Anvil:
This is the rigid base of the forging hammer. The anvil holds the lower half of the forging die.

(4) Die:
The forging die decides the shape of the forging components. The bottom half of the forging die is
fixed with the anvil, and the top half of the die is fixed with the ram.

(5) Ram:
The ram goes up and down and thus deforms the billet (or work piece) to desired shape.

(6) Board:
It is the stem connected to the ram. Board goes up by friction wheels.

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(7) Friction Rolls:
The friction rolls grip the board to drive it upward, once the ram reached to the highest position
friction rolls loosen its grip and the ram freely fall and hit the billet. Thus the ram falls in quick
succession to make a forged component. Instead of friction rolls, the ram can be powered by a belt
and a motor as well.

2.9 Requirements for forging:

(1) Aisles:
An aisle for vehicular traffic shall be not less than the width of the widest vehicle or load plus 3
feet. An aisle shall be outlined by marking.

(2) Platforms:
A platform used on the floor in front of a machine shall be designed to hold the weight imposed on
it without creating a tripping hazard.\

(3) Lighting and controls:

(a) Machinery and equipment shall be provided with a minimum of 15 footcandles light intensity to
fall upon the general area. When natural light is insufficient, artificial light shall be provided. Direct
or reflected glare and shadows, including moving shadows, should be avoided.
(b) A manually operated valve or switch for power forging equipment shall be identified as to
function and accessible to the operator.

(4) Use of lead:

The following safety requirements apply to lead casts or other use of lead in a forge shop or die
shop:
(a) Thermostatic control of heating elements shall be provided to maintain melting temperature at
not more than 750 degrees Fahrenheit.
(b) A covered container shall be provided to store dross skimming.
(c) Equipment shall be kept clean, particularly from accumulations of lead oxide.
(d) A sign shall be posted in the work area prohibiting eating in the area and calling attention to
dangers of oral ingestion of lead dust from hands and clothing.

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(5) Scale removers, oil swabs, and tongs:
(a) If an oil swab, scale brush, or other device is required to remove scale, it shall be long enough to
enable the employee to perform the job without placing his hands within the point of operation.
(b) Tongs shall be of sufficient length to clear the body of the worker in case of kickback, and shall
not have sharp handle ends. The worker should be instructed in the proper body position when
using tongs. Tongs should be checked periodically to see that they remain at the proper hardness
level for the job. When rings or equivalent devices for locking tongs are used, they should be
inspected periodically to ensure safe condition

2.10 Personal protective equipment:

(1) Protective goggles or spectacles shall be provided to, and used by, all employees where a face
and eye hazard exists. Protective goggles and spectacles shall comply with the requirements of
general industry safety standard, Part 33. Personal Protective Equipment, being R 408.13301 et seq.
of the Michigan Administrative Code.
(2) Head protection shall be provided to, and used by, all employees where a head hazard exists.
Head protection shall comply with the requirements of general industry safety standard, Part 33.
Personal Protective Equipment, being R 408.13301 et seq. of the Michigan Administrative Code.
(3) Foot or toe protection shall be provided to, and used by, all employees in accordance with
general industry safety standard, Part 33. Personal Protective Equipment, being R 408.13301 et seq.
of the Michigan Administrative Code, where a foot or toe hazard exists.
(4) Other types of personal protective equipment, such as aprons, spats, sleeves, and specialty
gloves other than lightweight cotton or similar types of gloves, shall be provided to, and used by,
employees when such personal protective equipment is required for the protection of the employee
from hazards.

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 Fig 2.13 PERSONAL PROTECTIVE EQUIPMENTS

2.11 Other machines:

(1) Power shears:
(a) The maximum size and specification of material being sheared on a power shear, as
recommended by the manufacturer of the shear, shall not be exceeded.
(b) Effective point-of-operation guarding shall be provided at both the feeding end and discharge
end of a power shear.

Fig2.14 POWER SHEAR MACHINE

(2) Power presses:

(a) A trim press shall be provided with a main disconnect switch as prescribed in R 408.14247(1).

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(b) A trim press shall be provided with a safety block or prop as prescribed in R 408.14243. Die
design shall take into consideration and provide a suitable flat area in the die for locating and using
blocking material.
(c) A trim press shall be fed by devices as prescribed in R 408.14251(10).

Fig.2.15 POWER PRESS

(3)Heating furnaces:
(1) A billet heating furnace shall be equipped with an automatic valve on the main fuel line which
will shut off in case of electrical or fuel supply failure.
(2) Radiant heat from a billet furnace shall be controlled by 1 or more of the following methods:
(a) Reflective shields of aluminum or materials of equal reflectivity.
(b) Controlled openings.
(c) Evaporative cooling.
(d) Water jackets.
(e) Chain curtains.
(3) An exhaust system shall be provided as prescribed by the State Department of Licensing and
Regulatory Affairs.

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 Fig 2.16 HEATING FURNACE

(4) Overhead crane:

Fig 2.17 OVERHEAD CRANE

An overhead crane, also known as a bridge crane, is a type of crane where the hook-and-line
mechanism runs along a horizontal beam that itself runs along two widely separated rails. Often it is
in a long factory building and runs along rails along the building's two long walls. It is similar to a
gantry crane. Overhead cranes typically consist of either a single beam or a double beam
construction. These can be built using typical steel beams or a more complex box girder type.
Pictured on the right is a single bridge box girder crane with the hoist and system operated with a
control pendant. Double girder bridge are more typical when needing heavier capacity systems from

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10 tons and above. The advantage of the box girder type configuration results in a system that has a
lower deadweight yet a stronger overall system integrity. Also included would be a hoist to lift the
items, the bridge, which spans the area covered by the crane, and a trolley to move along the bridge.

2.12 Hammer installation:

(1) A hammer shall be installed on or anchored to a foundation of such strength as to support the
imposed weight and normal work stress.
(2) A press shall be installed in a manner that it will remain in position or it shall be anchored to a
foundation of such strength as to support the imposed weight and normal work stress.

2.12 Inspection:
(1) Daily visual observation, without dismantling, shall be made of a forging hammer and forge
press to insure the safe condition of bolts, screws, keys, valves and all parts of treadles and clutches
and other operating mechanisms that might become loose by vibration.
(2) A periodic and regular maintenance safety inspection shall be made of forging machinery and
equipment, including guards and point of operation protection devices by a trained and authorized
employee.
(3) A record shall be made and maintained to show the date of inspection, equipment number and
condition found

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CHAPTER 3

CONCLUSION
My training was the most versatile experience. I had the pleasure to do the work with one of the most reputed
factory in their field- PUNJAB TRACTORS LTD. I received the blend of experience in Private as well as in Govt.
sector. It was a good learning time during my training as we were fortunate to be placed in the department
related to manufacturing. I feel training has given me exposure to undergo projects in the Manufacturing field
as well help me a lot to understand the company work culture, working with teams and much more. In the end
I will like to thank all persons who helped me throughout my training to enhance my experience. I also pay my
regards to my Lecturers for their guidance during my training and my Academics helped me to do a lot during
my training.

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