ABOUT BHARAT FORGE

Bharat Forgeis aforgingcompany based inPune,

India. Bharat Forge Ltd. (BFL) is a subsidiary of the
Kalyani group which was founded by Nilkanthrao
Kalyani. Currently the chairman of the company is
B.N. Kalyani, son of Dr. N Kalyani. Bharat Forge
came into existence in year 1961. Forging began in
1967. The forging was carried out through hammer
forging. In 1991, first Forging Modernization Division
(FMD I) was established.
The total cost for setting up the division was about
150 crores.
The world's largest forging company with
manufacturing facilities spread across India, United
States, Germany ,China and Sweden, Bharat Forge
manufactures a wide range of high performance,
critical & safety components for the automotive &
non-automotive sector. It is India's largest
manufacturer and exporter of automotive
components and leading chassis component
manufacturer in the world. BFL's customer base
includes virtually every global automotive backed
by several decades of experience in component
manufacturing & metallurgy, the company is now
looking beyond automotive and has embarked on
an ambitious and exciting journey to redefine its
already existing presence across several critical
business verticals such as oil & gas, power,
locomotive & marine, aerospace, metals & mining,
construction and general engineering

In Bharat Forge Ltd. products are produced both by

Closed Die Forging process
Open Die Forging process
Generally closed die forging process is used to
produce automobile components like Crankshafts,
Connecting Rods, and Axle Beam etc. While open
die forging is used for producing components of
various sectors like Marine, Defence, Aerospace,
and Oil &Gas.

Bharat Forge Ltd (BFL) Mundhwa plant is

divided into following major departments:

Sales/ITD (International Trade Dept.)

Profit Planning Control (PPC)
Material Dept.
Finance
Human Resource (HR)/ IR
Safety
Closed die forging division (CDFD)
Engg.
Die Shop
Forge Shop (FMD I/II/III, HFD I/II)
Heat Treatment
Machine Control Division I/II
MTB
Metallurgical Quality Control
Security

Closed Die Forging Division Engg:

In order to produce a customers product, it first has to be

designed virtually. This task comes under CDFD Engg. which
makes use of many designing and simulating softwares to
estimate, design and optimize a given specimen.The process
starts with estimation of force and energy required for the job
by using Ansys which is determined by the 2-D or 3-D
drawings given by the customer.
Then it is sent to the design team which designs the tooling
and die required for the job with the help of AutoCAD. Once
the die is designed, it is sent to CAD department for its 2-D
drawings to be generated which is carried out with the help of
softwares like Unigraphics, Catia and ProE. Afterwards, a 3-D
simulation software (Forge or Deform) gives necessary data
about the thermal, defect, stress and energy distribution in
the forging. Finally, the drawing and model are sent to the
CAM department which writes the program for the CNC
machines to produce the required die. Finally the drawing is
optimized using various software.

Die Shop

Once the CDFD Engg. has issued the

programs for CNC machines, the dies are
manufactured in the die shop. The general
process outlook is as follows.
Firstly planning of the die to be manufactured
for the given product is made i.e. the amount
of time required for the manufacturing of the
die prior to product manufacturing. . Finally
dies are manufactured as per the required
specifications in High Speed Milling Machines
(HSM). After this if there is any wear or
irregularities are there in the dies, then it is
removed either through welding (in case of
smaller dies) or CNC machines (for bigger
dies). Finally surface finishing of the dies are
made through Electron Discharge Machine
(EDM) followed by Benching (i.e. polishing of
the die). Then the die is checked in CMM and
LMM machine for any defect present in the
die after final finishing of the die.

Heat Treatment

After press forging, the products are quenched

and thus, develop brittleness or sometimes, a
customer has a special demand of heat
treatment of the product. Whatever the case
maybe, all the heat treatments are carried out
by this department. Various processes
available are annealing, normalizing,
hardening, nitriding (exclusively for dies),
carbo-nitriding, iso-annealing and carbon
restoration. Annealing is process by which any
residual stress due to thermal or mechanical
loading is relieved by heating.Carbo-nitriding
is the process by which case hardening is
achieved for gears and other products.The
shop has both batch-type and continuous-type
furnaces. Various quenching media are used
which include water, oil, polymer and even air.

Forge Modernization Division I

(FMD I)

This department came into existence in

1991. It is a press forge and houses 5
presses namely,
PTS 900 (16500 MT): It is a mechanical
press and is the largest in BFL.
PSH 4.560 (4560 MT): It is a screw press
and uses a large flywheel for energy
transfer.
LKM 400 (4000 MT)
LKM 2.500 (2500 MT)
LMZ 2500 (2500 MT)
The general process of the division is as
follows:
First billets are cut into suitable sizes and
heated in an oil-fired surface to a
temperature of 1280 degrees Celsius.
The heated billets are de-scaled with
water jets at high pressure.
Then they are put into dies and pressed
till they take the shape completely.

Forge Modernization Division II

This shop also follows the same process of
forging as that of the FMD I/III. Firstly raw
material as per the given specification of the
product are sorted and cut in a band saw to
the required dimensions. Then similar to FMD
I here also the cut billet is heated in the oil
furnace where 72 billets are heated
simultaneously. After this the same
procedure as that of FMD I/III is followed of
that of upsetting, trimming and padding.
FMD II shop contains screw presses of
different capacity
16000 ton
6000 ton
5000 ton
2500 ton

Forge Modernization Division III

This division of Bharat Forge Ltd. comes under
closed die Forge division. Generally in this
division the process used for forging is similar to
that of FMD I/II. This shop contains three screw
presses, which are of following capacity
12500 metric ton
8000 metric ton
5500 metric ton
In this division firstly the raw materials in the
forms of billets are cut into the required
dimensions as per the customers specifications
for the product. Then after this jobs were heated
simultaneously in the oil furnace for a
temperature range of 1230-1300 Celsius. Then
we pass the heated job through rolling machine
in order to increase its length and reduces the
cross sectional area. After that job is sent to
main press where firstly job is placed in the
blocker die followed by finishing die in order to
give the required shape. Then it is sent to
trimming press where the flash produced during
the forging is cut out. After this job is moved to
padding press where it is straightened i.e. any
bending that is present in it is removed. Finally
finishing is performed using short blasting or
short peening.


Heavy Forge Division I/II

This division comes under open die forging. These two shop is
generally used to produce products of critical shapes , which
cannot be produced by the closed die forging method. The
products which are usually produced in this shop are wind mill
shafts, gear blanks, mining manifolds, camshafts etc.HFD I
shop contains a hydraulic press of 1600 Ton capacity
(ZDAS).The shop also contains QKK12T manipulator having
carrying capacity of 12 Ton and travel speed of 20-40 m/min.
Similarily HFD II contains hydraulic press of 4000 metric ton
aswell as manipulator similar to that of HFD I. The shop also
contains various types of furnaces like
Slow cooling furnace
Normalizing furnace
Tempering furnace

Forge Shop
This the oldest forging shop in Bharat Forge
which uses Manual forging technique unlike
FMD I/II/III which uses automatic forging
machines. This shop contains Hammer Machine
that is used for the forging of the job. Generally
it is used to produce heavy or complex shape
products, which cannot be manufactured, by
FMD I/II/III shop.This shop can forge the given
job both vertically as well as horizontally unlike
FMD in which only vertical forging is
done.Hammer used for forging in this shop is
around 25000 pound.Hence it is not used for
mass production but only for the production of
the complex shapes.

Machined Components Division (MCD I)

MCD I is responsible for the grinding and finishing
of the crankshafts that come out of the pressing
shops. This shop has 11 lines for crankshaft
finishing and 6 lines for non-crankshaft products
(such as FAB assembly, knuckle, reinforcement
brackets and Al forgings). All the output of this
shop is for domestic sales only.The processes
carried out on each line are roughly thesame
which include milling of crank pin and journal,
grinding of pin, journal, flange and thrust collar,
cutting of key-slot, drilling of centre holes and
super-finishing of the pin and journal to an
average roughness of 0.07m. Finally it is checked
for the correct dimension using different types of
gauges.

Machined Components Division II(MCD II)

This department was set up in 2004 and is fully
automated. It has 4 production lines and produces
fully-finished crankshafts exclusively for
export.The gantry system is fully automatic which
reduces production time and lot rejection, even
with 24 machines per line.The process sequence
is similar to that of MCD I which includes grinding
of flange, pin, journal, thrust collar, super-finishing
of pin and journal, cutting of keyways, drilling of
end-holes. The division produces 800 jobs per day.
Tac time is 6.88 minutes per job.

Metallurgical Quality Control

Division
MQC division is responsible for the control of
material quality that is used in the forging, both
for dies and forgings. It houses apparatus for
Jominy end-quench test, Kinematic viscosity test,
Universal tensile test machine, Hardness
machine etc. It carries out various tests on
materials to find out the different physical and
chemical properties of raw materials which are
different grades of steels. Physical properties are
also determined through microstructures which
are seen through high magnification
microscopes. Chemical properties are
determined from the composition of the forging
material.

Machine Tool Building (MTB)

MTB is a research and development department
which caters to the needs of the other
departments. Its main objectives are to procure
machinery for BFL, re-condition grinding and
milling, make super-finishing, gear-cutting and
hobbing machines. Another important objective
of this division is to procure old machines and
repair them for further usage. A brand-new
machine is very expensive whereas an old
machine can be bought and repaired quite
cheaply. These machines are for BFL plants only
and are not sold outside the company.

A2 Line
This shop is generally performed the final
machining and painting of the products like
crankshafts and front axle. Firstly the parting
line grinding of the job is done through a
robotic machine (special purpose machine).
Then end grinding of the job is done followed
by straightening and untwisting of the job.
After this job is sent for visual inspection in MPI
(Magnetic Particle Inspection) where job is
magnetized and then seen under UV rays in
order to find whether there is any crack is
present in work piece or not.

International Trade Division

(ITD)/Sales
The marketing and sale of products to overseas
buyers is carried out by the ITD. BFL exports
automotive parts to North and South America,
Europe, China and Japan and non-automotive
parts worldwide. There are teams to coordinate
such sales, which are:
Documentation and Logistics team: They handle
all the documentation and transport of the
products. 99% of the product sold overseas is
shipped through cargo ships.
Sales and Marketing team: This team is
responsible for capturing clients and expanding
the companys foreign clientele. It markets the
companys products to potential buyers.
The domestic marketing and sale of the product
is carried out by the sales deptt. The procedure of
sales deptt. Is similar to that of ITD starting from
product purchase till the dispatch of the of the
product to the customer.

Safety
It employs 39 safety engineers and 23 fire
engineers which are trained in fire-fighting and
safety measures should the need arise. Each
department has an HSE (Health, Safety and
Environment) Representative who is responsible
for the safety regulations to be followed.
For safety regulations to be employed, one needs
HIRA (Hazard Identification and Risk Assessment).
BFL employs Croners method for HIRA. Another
lever is the BBS or the Behaviour Based Safety
which divides workers behaviours into two
categories Safe and Atrocious. Safe behaviour is
what the worker should exhibit as is expected
from him/her as per the guidelines.
Each department is to carry out the following
safety drills:
1. Plant safety inspection of one line per section
per week.
2. Identification of two hazards per line per
section and implementation of its control.
3. One safety meeting per month.
4. Weekly tool box talk per line per section.
5. Reduction of oil consumption by eliminating
oil leakage and spillage.
6. One department of fire audit per month.
7. Fire Risk Assessment of one line per section
per week
8. One equipment audit per month.
9. One safety Kaizen or suggestion per line per

Security

Bharat forge Ltd is in 86 acres Surrounded with 6 feet

high stonewalls and barbed wire. There are 100
guards in total at Bharat forge working in groups of 30
in 3 shifts. The next step in the security is the access
control where each of the employees are given the
smart card and the visitors as well as the contract
workers are given the manual or smart passes. There
is DFMA and Security gate in order to check the
access of the individuals coming inside the premises