How to reduce hot forging costs through innovative techniques?

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COST REDUCTION IN HOT FORGING BY

INNOVATIVE TECHNIQUES

byby SRIKAR SHENOYSRIKAR SHENOY

GENERAL MANAGER

211, RAIKAR CHAMBERS, GOVANDI EAST,

MUMBAI–400 088. INDIA.

Tel. : 91-22-6797 8060 Fax : 91-22-2555 2459

Mobile: 9820493373

Email : info@steelplantspecialities.com

Website : www.steelplantspecialities.com

: SINCE 1985

Solving Problems Systematically

Through

• Innovative, customised products.

QUICK FACTS ABOUT SPS

Incorporated in 1985 by seasoned metallurgical engineers from Indian Institute of Technology, Mumbai.

Manufactures range of products for heat treatment, hot forging and hot rolling industries. ISO certified.

Sole supplier of specially developed niche products to industry leaders.

1. Cost Reduction through

Protective (anti-scale) coatings that prevent or minimize:

Oxidation (scaling) & decarburization during hardening, normalizing, hot rolling & hot forging.

Quench cracking. Shot blasting / pickling operations. Rejections during re-HT

HARMFUL EFFECTS OF OXIDATION AND HARMFUL EFFECTS OF OXIDATION AND DECARBURISATIONDECARBURISATION

1. Loss of dimension.2. Deterioration of surface quality, i.e., pitting.3. Non-uniform metallurgical transformation during hardening. 4. Lowered surface hardness and strength.5. Reduced fatigue life of heat treated product.

Concept: Protective Coatings to Concept: Protective Coatings to Prevent or Minimize OxidationPrevent or Minimize Oxidation

Oxidation & decarburization occur during heating in open air atmosphere due to surface reaction of metal and carbon with oxygen, and products of combustion.

STEELAIR

PREVENTING OXIDATIONPREVENTING OXIDATION

PROTECTIVE COATING

Protective anti-scale coatings form a barrier on metal that prevent reaction of metal with oxygen.

Hence, oxidation is either prevented or delayed.

Coated Billets before Hot Forging

Coated Components

before Heat Treatment

Characteristics of Characteristics of ESPON anti-scale coatingsESPON anti-scale coatings

Do not react with metal.

Do not emit toxic fumes during storage, use or during heating the coated job.

Non-hazardous.

Economical. Method of application: Brushing, Dipping or Spraying

Benefits of using protective coatings:Benefits of using protective coatings:

1. Preventing scaling and decarburization.

2. Preventing rejections due to quench cracking.

3. Elimination or minimization of post heat treatment operations like grinding, shot blasting or acid pickling.

4. Preventing rejections during re-heat treatment and re-re-working.

The next illustration shows material saving of more than 10% in an expensive metal alloy hot rolling operation.

Process improvement of 50% was noted due to reduction in grinding.

Huge savings were made possible by use of ESPON anti-scale coating.

CR Sheets

4300 mm X 1100 mm X 4.5 mm

ANNEALING

950ºC/30 mins./

air-cool to room temperature

HOT LEVELLING

820ºC/60 mins.

GRINDING

FINAL THICKNESS

3.7 mm

USE PROTECTIVE COATING

SCALE PREVENTION = MATERIAL SAVING + PRODUCTIVITY IMPROVEMENT

CR Sheets

4300 mm X 1100 mm X 4 mm

ANNEALING

950ºC/30 mins./

air-cool to room temperature

HOT LEVELLING

820ºC/60 mins.

GRINDING REDUCED BY 50%

FINAL THICKNESS

3.7 mm

Coated Split Rings before Heat Treatment.

After Heat Treatment & Shot Blasting

COATEDNOT COATED

Photo next to Customer’s Quality Department

Use of Protective Coating Use of Protective Coating

To To PreventPrevent Or Minimize

Rejections due to Quench Cracking

Product: Steering knuckle

Gear-end of crank shafts prone to quench cracks

To To EEliminate Or Minimize

Operations Like

Shot Blasting, Grinding, Or Acid Pickling after Heat

Treatment.

Preventing scaling on the inner surface of Forged Spindles

STEEL PLATES

ANNEAL

SHOT BLAST

DESPATCH

SHOT BLAST

ANNEAL AFTER ESPON COATING

SHOT BLAST

STEEL PLATES

DESPATCH

PRODUCTIVITY IMPROVEMENT DUE TO COATING

Above Details as confirmed by M/s. SAIL, Rourkela Steel Plant, Rourkela.

Salvage Rejected Components and to Prevent Salvage Rejected Components and to Prevent Rejections during Re-Heat TreatmentRejections during Re-Heat Treatment.

REJECTED COMPONENTS(HEAT TREATED)

(METALLURGICAL REASONS)

SCRAPSALVAGE BY

RE-HEAT TREATMENT USING

PROTECTIVE COATING

Re-Heat Treatment of Finish Machined Forged Spindles

Image on left shows heat treated spindles. Image on Right shows a re-heat

treated spindle. Zero Scaling + Aesthetic appeal

Heavy scaling leads to pit-marks on forgings during re-working.

Scale-pits are prevented by use of anti-scale coating during re-work. Identification numbers are intact.

Hot Forging Die Lubricants that:

Eliminate pollution

Are environment friendly

Ensure optimum die life

Enable smooth production in a number of hot forging operations

Are economical

Types of Hot Forging Lubricants Manufactured by SPS:

• Graphiteless, water soluble

• Graphite based, water miscible

• Special oil with graphite

• Special oil without graphite

• Uniformity in metal flow.

• Parting compound.

• Barrier to heat transfer.

• Prevent build up in die cavity.

• Be easily removable.

• Avoid explosion due to rapid phase change.

• Environment friendly.

• Economical.

CHARACTERISTICS OF ESPON DIE LUBRICANTS

METHODS OF APPLICATION

• Manual swabbing

• Dipping (extrusion punches)

• Manual Spraying

• Automatic Spraying

Coming up:

Case Studies of ESPON hot forging die lubricants as confirmed by customers in India and some testimonials.

Productivity Improvement

Particulars Graphite Based Lubricant

Graphiteless Lubricant ESPON-

1. Forging equipment 1000 Ton Press

2. Product Sleeves

3. Dilution ratio 1:10 1:10

4. Time loss due to die grinding at each shift

1.5 hrs NIL

5. Production per day 7000 9000

6. Productivity improvement -- 22%

Cost Benefit Analyses 1

Particulars Lubricating Oil Graphiteless Lubricant ESPON-GLF3

1. Forging Equipment 1000 Ton Press

2. Product Companion Flange

3. Die Life 4500 6000

(33% Improvement)

4. Price Rs. 24/- per ltr. Rs. 17/- per ltr.

(1:7 dilution)

5. Application Swabbing Spraying

6. Pollution Heavy smoke Clean environment

Cost Benefit Analyses 2

Particulars Lubricating Oil Graphiteless Lubricant ESPON-GLF3

1. Forging Equipment 1600 Ton Press

2. Product Input Shaft (Indica car)

3. Die Life 5000 7000

(40% Improvement)

4. Price Rs. 24/- per ltr. Rs. 12/- per ltr.

(1:10 dilution)

5. Application Swabbing Spraying

6. Pollution Heavy smoke Clean environment

Seeing is Believing!

• Application Videos.

Videos of ESPON hot forging lubricants and Spraying Equipments in action available on given links:

Oil lubricant on 1000 ton press: http://bit.ly/dielubeOil

ESPON Environment friendly lubricant on 1000 ton press: http://bit.ly/ESPON-DEL3

Environment Friendly Indeed!

• MITCON Tests.

Workzone Air Quality Comparison Summary.

Parameters Units Imported Graphite Based Lubricant

Graphiteless Lubricant

Suspended Particulate Matter

µ g/m3 509 362

(29% Less)

Sulphur Dioxide µ g/m3 33.60 32

Oxides of Nitrogen µ g/m3 42.50 41

Carbon Monoxide µ g/m3 8 3

(63% Less)

Zero Maintenance Die Lubricant Spraying Systems

Ideal Features of Die Lubricant Spraying System:

Ability to deliver all types of die lubricants.

Continuous automatic stirring / agitation.

Quick re-filling.

Economical.

Long life and low running costs.

Zero unplanned downtime.

Low maintenance.

Low inventory costs.

Diaphragm Pump Spraying Equipment

Ability to deliver all types of die lubricants. Continuous automatic stirring / agitation. Quick re-filling. Economical. Long life and low running costs. Zero unplanned downtime. Low maintenance. Low inventory costs.

Conventional Pressure Feed Tank

Pressure Feed Tank with Motor

Ability to deliver all types of die lubricants. Continuous automatic stirring / agitation. Quick re-filling. Economical.Long life and low running costs. Zero unplanned downtime. Low maintenance. Low inventory costs.

Zero Maintenance Pressure Feed Tank

Videos

Accessories - Sprayguns

Accessories – Foot Operated Spray + Nozzles

Accessories – Spray Nozzles

SUMMARY

Substantial cost reduction in hot forging is possible by the use of:

1.Protective anti-scale coatings

2. Environment friendly forging die lubricants

3. Zero Maintenance Spraying Systems

Manufactured by SPS.

TESTIMONIALS

Testimonials from industry leaders who are regular satisfied users of ESPON products mentioned in this presentation are available on request.

We put new LIFE into your die and forging process!

www.steelplantspecialities.com