Forging is a manufacturing process involving the shaping of metal using localized compressive forces. The blows are delivered with a hammer (often a power hammer ) or a die . Forging is often classified according to the temperature at which it is performed: cold forging (a type of cold working ), warm forging, or hot forging (a type of hot working ). For the latter two, the metal is heated , usually in a forge . Forged parts can range in weight from less than a kilogram to hundreds of metric tons. Forging has been done by smiths for millennia; the traditional products were kitchenware , hardware , hand tools , edged weapons , cymbals , and jewellery .
95-512: Bharat Forge Limited is an Indian multinational company involved in forging , automotives, energy, construction and mining, railways, marine, aerospace and defence industries. The company was founded by Nilkanthrao A. Kalyani on 19 June 1961. Headquartered in Pune , Maharashtra , it is the flagship company of the Kalyani Group . Bharat Forge's Special Economic Zone (SEZ) named Khed City
190-518: A 40% stake in Kalyani Sharp India Ltd. in 1990. The company was renamed Sharp India Ltd. in 2005. Alstom Bharat Forge Power Limited was a joint venture with French company Alstom . Originally, Alstom held a 51% stake and Bharat Forge held the remaining 49%. Alstom's shares were acquired by American conglomerate General Electric on 25 November 2015 as part of its global acquisition of Alstom's energy business. Alstom Bharat Forge won
285-540: A 51% share in Indian subsidiary of Zorya Mashproekt . On 9 May 2023 the company signed the acquisition agreement. The acquisition process was finished on 31 December 2023. Indian Navy has consulted Bharat Forge to develop and supply marine gas turbine engine given the Russo-Ukrainian War that has impacted Zorya-Mashproekt, the primary supplier. According to reports that emerged on 14 May 2024, Bharat Forge
380-616: A 51% stake, while Rafael holds the remaining 49%. The Kalyani Group claimed that it was the first private sector advanced defence subsystems manufacturing company in India. KRAS manufactures electro-optics, remote weapon systems, precision guided munitions and system engineering for system integration. KRAS established a 24,000 sq ft defence manufacturing facility in Hyderabad , Telangana in August 2017. The first product planned to be produced at
475-596: A committee was formed to suggest reforms and overhauls. The 9-member committee, which was under the Prime Minister’s Office (PMO), was led by former Principal Scientific Adviser to the Government of India K. Vijayraghavan . The committee submitted its report on the reforms for DRDO in July 2024. Reportedly, the recommendations from the committee have been described as contentious and it was also reported that
570-422: A component requires high strength ; such forgings usually require further processing (such as machining ) to achieve a finished part. Today, forging is a major worldwide industry. 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
665-685: A contract to supply two units of 660 MW supercritical coal turbines to NTPC Limited for a power plant in Solapur , Maharashtra. Alstom Bharat Forge began production of supercritical turbines and generators at a new manufacturing facility at Sanand , Gujarat in May 2016. The company won a contract to supply two units of 800 MW ultra-supercritical steam turbine generator islands for the Telangana Super Thermal Power Project Phase-1 near Ramagundam . On 8 November 2016,
760-420: A distinctly different flow pattern. Both of these machines can be used for open-die or closed-die forging. 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
855-588: 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 time-consuming 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
950-425: A hammer strikes and deforms the workpiece, which is placed on a 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. The operator therefore needs to orient and position the workpiece to get the desired shape. The dies are usually flat in shape, but some have
1045-407: 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. Defence Research and Development Organisation The Defence Research and Development Organisation ( DRDO ) ( IAST : Raksā Anūsandhān Evam Vikās Sangaṭhan )
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#17327827249811140-437: 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
1235-455: A new company named BF Utilities Limited on 15 September 2000. Bharat Forge recorded an all-time revenue high of ₹ 10,146 crore (US$ 1.2 billion) in 2019. The company's market capitalization reached an all-time high of ₹ 5,415 crore (US$ 650 million) in 2021. In October 2024, Bharat Forge acquired AAM India Manufacturing (AAMIMCPL), a subsidiary of American Axle & Manufacturing Holdings , for ₹544.5 crore. Currently Bharat Forge
1330-537: A pan tilt platform. On 28 December 2021, Defence Institute of Physiology and Allied Sciences (DIPAS) transferred technology to manufacture extreme cold weather clothing system to RHD Business Services, SBNX Innovation, Shiva Texyarn Limited, Kusumgar Corporates and Ginni Filaments Limited. DRDO on 8 January 2024 launched Ugram, an assault rifle chambered in 7.62x51mm NATO , which has been designed, developed and manufactured in collaboration with Dvipa Armour India Private Limited under DcPP. It's scheduled to be tested by
1425-437: A particular process window. To provide good forming conditions a homogeneous temperature distribution in the entire workpiece is necessary. Therefore, the control of the tool temperature has a major influence to the process. For example, by optimizing the preform geometries the local effective strains can be influenced to reduce local overheating for a more homogeneous temperature distribution. High-strength aluminium alloys have
1520-472: A portable backpack type that covers an area of 300 metres while another trolley mounted for large area sanitisation of up to 3000 metres by spraying 1% hypochlorite solution. Vehicle Research and Development Establishment (VRDE) developed a portable disinfection chamber and special face protection mask for health professional combating the COVID-19 outbreak in India. The personnel decontamination system
1615-508: A private sector industry. On 16 December 2021, Ashok Leyland signed partnership agreement with Combat Vehicles Research and Development Establishment (CVRDE) to develop 600 hp engine for Future Combat Vehicle Programme. Instruments Research and Development Establishment (IRDE) on 27 December 2021 transferred technologies for developing border surveillance system to Indian private sector company Paras Defence and Space. The system consists of radar, and electro-optical sensors mounted on
1710-666: A product called Aerosol Containment Box for enclosure of intubation procedure made with Poly(methyl methacrylate) . It is cubical designed for both adults and minors and covers the COVID-19-infected patients during medical examination and treatment from head to chest to stop the transmission of droplets containing the virus to others. Employees' State Insurance Corporation Medical College, Hyderabad helped RCI in prototype development while Postgraduate Institute of Medical Education and Research helped in testing, validation and acceptance of products for medical use. The technology
1805-417: 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 forgings can be worked into shapes which include discs, hubs, blocks, shafts (including step shafts or with flanges), sleeves, cylinders, flats, hexes, rounds, plate, and some custom shapes. Open-die forging lends itself to short runs and
1900-543: Is India's largest and most diverse research organisation. The organisation includes around 5,000 scientists belonging to the DRDS and about 25,000 other subordinate scientific, technical, and supporting personnel. The DRDO was established in 1958 by combining the Defence Science Organisation and some of the technical development establishments. A separate Department of Defence Research and Development
1995-451: Is a forging process where a hammer is raised and then "dropped" into the workpiece to deform it according to the shape of the die. There are two types of drop forging: open-die drop forging and impression-die (or 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 forging is also known as smith forging . In open-die forging,
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#17327827249812090-887: Is an agency under the Department of Defence Research and Development in Ministry of Defence of the Government of India , charged with the military 's research and development , headquartered in Delhi, India. It was formed in 1958 by the merger of the Technical Development Establishment and the Directorate of Technical Development and Production of the Indian Ordnance Factories with the Defence Science Organisation under
2185-412: 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 the 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
2280-399: Is collaborating with Mysore-based Skanray Technologies for the production of ventilators using currently available technologies with Indian made parts due to unavailability of imports. It is also working on a new multiplexed ventilator technology that will be able to support several infected individuals on a single ventilator. The prototype development stage is complete and the initial model
2375-401: 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 it can be done more quickly and precisely, and as the metal is deformed work hardening effects are negated by the recrystallization process. Cold forging typically results in work hardening of the piece. Drop forging
2470-496: Is developing an Infantry Combat Vehicle under Indian Army's futuristic infantry combat vehicles (FICV) programme on par with DRDO Abhay IFV . Bharat Forge is also developing a Light Tank under 25 tonnes to compete L&T's Zorawar Tank in the Army's light tank programme. Kalyani Rafael Advanced Systems (KRAS) is joint venture between KSSL and Israeli defence company Rafael Advanced Defense Systems established in 2015. KSSL holds
2565-401: Is equipped with sanitiser and soap dispenser. The full-body decontamination starts using for pedal with an electrically operated pump creating a disinfectant mist of 700-litre of hypo sodium chloride. The system takes 25 seconds for full decontamination with an automatic shut-off procedure and can decontaminate 650 personnel until the next refill. The face mask developed for COVID-19 patients uses
2660-456: Is forming of a work piece in a single step in several directions. The multidirectional forming takes place through constructive measures of the tool. The vertical movement of the press ram is redirected using wedges which distributes and redirects the force of the forging press in horizontal directions. Isothermal forging is a process by which the materials and the die are heated to the same temperature ( iso- meaning "equal"). Adiabatic heating
2755-406: Is helping Lakes and Waterways Development Authority (LAWDA) to keep Dal Lake clean by providing low cost Biodigesters for the treatment of human excreta , animal waste disposal, grey water and kitchen waste release that works fine in ambient as well as sub zero temperature which are also supplied to Indian Railways . Defence Research and Development Establishment (DRDE) which works in
2850-427: Is its ability to deform the complete workpiece. Drop-hammer forging usually only deforms the surfaces of the work piece in contact with the hammer and anvil; the interior of the workpiece will stay relatively undeformed. Another advantage to the process includes the knowledge of the new part's strain rate. By controlling the compression rate of the press forging operation, the internal strain can be controlled. There are
2945-726: Is made up of high strength polyester coated with breathable polymer. The clothing underwent successful trials at the South India Textile Research Association and exceeds the criteria of currently available suits in the market. The suit is washable, passed all critical CBRN and ASTM standards and is now manufactured by two private players, Venus Industries from Mumbai and IMTEC from Kolkata . Defence Bioengineering and Electromedical Laboratory (DEBEL) developed causality evacuation bag for COVID-19 infected patients that can withstand Chemical, Biological, Radiological and Nuclear (CBRN) environments and
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3040-472: Is mainly used for aerospace applications. Magnesium alloys are more difficult to forge due to their low plasticity, low sensitivity to strain rates and narrow forming temperature. Using semi-open die hot forging with a three-slide forging press (TSFP) has become a newly developed forging method for Mg-Al alloy AZ31, commonly used in forming aircraft brackets. This forging method has shown to improve tensile properties but lacks uniform grain size. Even though
3135-448: Is most common when parts are forged without heating the slug, bar or billet. Aluminum is a common material that can be cold forged depending on final shape. Lubrication of the parts being formed is critical to increase the life of the mating dies. 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. Multidirectional forging
3230-447: 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 (2,190 to 2,370 °F) in less than 60 seconds using high-power induction coils. It
3325-552: Is now transferred to private industries located in Chandigarh and Hyderabad for mass manufacturing. RCI at DRDO Missile Complex, Hyderabad is now supplying technology of brushless DC motors (BLDC) used for missile actuators and high response solenoid valves used in missile control for ventilator pumps that validated the prototype testing stages. Centre for Fire, Explosive and Environment Safety (CFEES) developed two sanitising equipment of 50 litres tank capacity consisting of
3420-588: Is now undergoing various improvements suggested by a team of medical researchers and doctors. The technology will finally be transferred to Tata Motors , Mahindra and Mahindra , Hyundai Motor India , Honda Cars India and Maruti Suzuki for immediate mass production. DRDO signed agreement with Indian Telephone Industries Limited for tech transfer on low cost multiplexed ventilator technology with 80% to 90% of components are now make in India . DRDO as of 11 April 2020 transferred technologies to 30 major companies to manufacture various non-medicine products against
3515-460: Is one of the major reasons closed-die forgings are often used in the automotive and tool industries. 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. Forging dies are usually made of high-alloy or tool steel . Dies must be impact- and wear-resistant, maintain strength at high temperatures, and have
3610-484: Is protected against blood and viral penetration. The bag is made up of durable water-repellent nonwoven fabric . It is rigid and cylindrical with air and waterproof zippers and ventilators. Already ordered 500 in numbers, DRDO will now transfer the technology to the private sector for manufacturing. Under the Society for Biomedical Technology (SBMT) programme, DEBEL has developed five-layer nanomesh based N99 masks and
3705-415: 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 spot 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
3800-454: 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
3895-510: Is spread over an area of 1,000 hectares (4200 acres) in Khed taluka , and is the largest SEZ in Pune district . It was the first company promoted by the Kalyani Group and remains the Group's flagship company. The current chairman of the company is the founder's son, Baba Kalyani . Bharat Forge's products include front axle beams, steering knuckles, connecting rods and crankshafts. The new strategy
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3990-464: Is the "world’s largest single location forging facility consisting of fully automated forging press lines and state-of-the-art machining facility." It has manufacturing operations in four locations: Bharat Forge Kilsta, Bharat Forge CDP, and BF Aluminiumtechnik are the company's Europe-based forging units. Other subsidiaries of Bharat Forge include: Kalyani Strategic Systems Ltd. (KSSL) is a defence manufacturer that supplies components and subsystems to
4085-403: 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
4180-517: Is to augument a strong global footprint in Lightweight materials. As part of its risk mitigation efforts, Bharat Forge diversified into a variety of industrial sectors including oil & gas, infrastructure, and marine. Some of BFL's largest customers include Daimler Group, VW Group, Meritor and Dana etc. The company also has an extensive collaboration with major truck manufacturers. Bharat Forge's Investment and Windmills divisions were demerged to
4275-407: Is used to assist in the deformation of the material, meaning the strain rates are highly controlled. This technique is commonly used for forging aluminium, which has a lower forging temperature than steels. Forging temperatures for aluminum are around 430 °C (806 °F), while steels and super alloys can be 930 to 1,260 °C (1,710 to 2,300 °F). Benefits: Disadvantages: Depending on
4370-560: The COVID-19 pandemic which includes ventilators, sanitiser, personal protective equipment , face shield and isolation shelters. The technology for the newly developed multiplexed ventilator came from the onboard oxygen generation system (OBOGS) developed for HAL Tejas . Private sector players like Raksha Polycoats and Accurate Savan Defence are now producing protective clothing, isolation shelters based on DRDO tech developed for high altitude pulmonary oedema (HAPE) bags, submarine escape
4465-591: The Indian Armed Forces , and exports to other countries. The company holds an Industrial License under the Arms Act, 1959 . In May 2021, Bharat Forge announced that it would raise its stake in KSSL from 51% to 100%. It provides a range of products including Artillery Systems, Protected Vehicles , Armored Vehicles Upgrades, Ammunition, Missiles, and Air Defense solutions. Kalyani Strategic Systems bought
4560-403: The die sooner than if there were no friction present, creating a much greater increase in the pressure required for the punch to finish the forging. 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
4655-641: The 1970s. Project Devil itself led to the later development of the Prithvi missile under the Integrated Guided Missile Development Programme (IGMDP) in the 1980s. IGMDP was an Indian Ministry of Defence programme between the early 1980s and 2007 for the development of a comprehensive range of missiles, including the Agni missile , Prithvi ballistic missile, Akash missile , Trishul missile and Nag Missile . In 2010,
4750-542: The A4 size Over-Head Projection (OHP) film for protection and lightweight materials for long duration comfortable use. VRDE developed full-body decontamination chamber was designed and validated within 4 days with All India Institute of Medical Sciences, New Delhi became the first premier institution to use it. The mass manufacturing of the portable decontamination chamber is now done by Dass Hitachi Limited. As part of Make In India and Atmanirbhar Bharat initiative, DRDO under
4845-645: The Advanced Numerical Research and Analysis Group (ANURAG) and Laser Science and Technology Center (LASTEC) are no longer functional as independent entities. The staff are relocated to various DRDO labs in Hyderabad. DRDO is planning to build a new research lab in Lucknow. India domestically produces only 45% to 50% of defence products it uses, and the rest are imported. To become technology research and production leader, reduce reliance on
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#17327827249814940-735: The DRDO has agreed to implement approximately 60% of the major reforms. As of October 2024, the implementation of structural reforms has been delayed due to opposition from senior DRDO officials. As part of the rationalization plan, the Defence Terrain Research Laboratory (DTRL) was merged with the Snow and Avalanche Studies Establishment (SASE) which was renamed into the Defence Geological Research Establishment (DGRE). As of 2020,
5035-532: The DRDO, including Varunastra, Maareech, Ushus, and TAL by the navy; Electronic Warfare Technologies, radars, composite materials for LCA, AEW&C, Astra, and LCA Tejas by airforce; and ASAT, BrahMos, ASTRA, Nag missile, SAAW, Arjun MBT Mk 1A, 46-metre Modular Bridge, MPR, LLTR Ashwin by the army. In September 2019, DRDO formulated the "DRDO Policy and Procedures for Transfer of Technology" and released information on "DRDO-Industry Partnership: Synergy and Growth and DRDO Products with Potential for Export" . During
5130-706: The Development cum Production Partner programme (DcPP) allowed handholding of domestic private sector industries to improve their development and production cycle of complex defence systems. VL-SRSAM (Vertical Launch - Short Range Surface to Air Missile) and Advanced Towed Artillery Gun System (ATAGS) became some of the successful projects of this programme. Hindustan Aeronautics Limited on 17 December 2021, secured an order for manufacturing, assembly, integration, testing and supply of DRDO Abhyas from Aeronautical Development Establishment . The order will be completed under Development-cum-Production Partner (DcPP) with
5225-679: The Vibrant Goa Global Expo and Summit 2019 in October, DRDO signed technology transfer contracts with 16 Indian companies , including 3 startups, to produce products for the use by Indian Armed Forces . This included high shelf life , high nutrition, ready-to-eat on-the-go food products to be consumed in the difficult terrain and bad weather. DRDO and ISRO have agreed to collaborate in India's crewed orbital spacecraft project called Gaganyaan during which DRDOs various laboratories will tailor their defence capabilities to suit
5320-408: The ability to withstand cycles of rapid heating and cooling. In order to produce a better, more economical die the following standards are maintained: Barrelling occurs when, due to friction between the work piece and the die or punch , the work piece bulges at its centre in such a way as to resemble a barrel . This leads to the central part of the work piece to come in contact with the sides of
5415-544: The administration of Jawaharlal Nehru . Subsequently, Defence Research & Development Service (DRDS) was constituted in 1979 as a service of Group 'A' Officers / Scientists directly under the administrative control of the Ministry of Defence. With a network of 52 laboratories that are engaged in developing defence technologies covering various fields like aeronautics, armaments, electronics, land combat engineering, life sciences, materials, missiles, and naval systems, DRDO
5510-488: The application of magnesium alloys increases by 15–20% each year in the aerospace and automotive industry, forging magnesium alloys with specialized dies is expensive and an unfeasible method to produce parts for a mass market. Instead, most magnesium alloy parts for industry are produced by casting methods. The most common type of forging equipment is the hammer and anvil. Principles behind the hammer and anvil are still used today in drop-hammer equipment. The principle behind
5605-549: The board of Bharat Forge approved the exit of the company from Alstom Bharat Forge Power. In March 2017, Bharat Forge announced that it would divest 23% of its shares to GE, and the remaining 26% stake was divested in February 2018 completing Bharat Forge's exit from Alstom Bharat Forge Power. Forging Since the Industrial Revolution , forged parts are widely used in mechanisms and machines wherever
5700-472: The defence minister A. K. Antony ordered the restructuring of the DRDO to give a major boost to defence research in the country and to ensure effective participation of the private sector in defence technology. The key measures to make DRDO effective in its functioning include the establishment of a Defence Technology Commission with the defence minister as its chairman. The programmes which were largely managed by DRDO have seen considerable success with many of
5795-468: The designer or Indian industry at par with their corresponding designer in the world market. If they could get a MiG-21 from the world market, they wanted a MiG-21 from DRDO. DRDO started its first major project in surface-to-air missiles (SAM) known as Project Indigo in the 1960s. Indigo was discontinued in later years without achieving full success. Project Indigo led Project Devil , along with Project Valiant, to develop short-range SAM and ICBM in
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#17327827249815890-475: The dies, allowing for easy automation. 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 . The machines are usually set up to work in
5985-434: The dies. 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,
6080-458: 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
6175-718: The facility was the Israeli Spike anti-tank guided missiles (ATGM). However, the Government of India assigned the ATGM programme to the Defence Research and Development Organisation , after which KRAS pivoted to producing Spice 2000 bombs. In July 2019, KRAS received a $ 100 million contract to produce 1,000 Barak 8 medium-range surface-to-air missiles (MR-SAM) for the Indian Army and Air Force . On 16 March 2021, KRAS announced that it had begun delivery of
6270-632: The field of chemical weapon , biological agent detection and research is helping Indian Council of Medical Research (ICMR) in augmenting diagnostic capability for COVID-19 outbreak. It has created special hand sanitiser formulation and diagnostic kits following WHO standards and guidelines that are supplied in large numbers to civilian and defence officials. Medical staff all over India dealing with Coronavirus contamination are using protective waterproof clothing with special sealant used in submarine applications developed by Institute of Nuclear Medicine and Allied Sciences (INMAS) for CBRN defence that
6365-445: 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. Near net shape forging
6460-485: The first batch of MR-SAMs. This was the second product built at the Hyderabad plant. Kalyani Telecommunications & Electronics Pvt. Ltd. was incorporated on 5 July 1985 by Bharat Forge. The company manufactured black and white and colour television sets , and videocassette recorders under the brand name Optonica. It became a public limited company on 20 September 1985. The company was renamed Kalyani Sharp India Ltd. on 2 May 1986. Japan's Sharp Corporation acquired
6555-450: 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
6650-402: The forming temperature steel forging can be divided into: For industrial processes steel alloys are primarily forged in hot condition. Brass, bronze, copper, precious metals and their alloys are manufactured by cold forging processes; each metal requires a different forging temperature. Due to the narrow temperature range and high thermal conductivity, aluminium forging can only be realized in
6745-456: The foundation. Moreover, a large machine base is needed to absorb the impacts. 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 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
6840-415: The high speed of automatic hot forging. 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 liquid propane (LP) gas cylinders. Manual transmission gears are an example of automatic hot forging used in conjunction with cold working. Roll forging is a process where round or flat bar stock
6935-446: The horizontal plane, to facilitate the quick exchange of workpieces from one station to the next, but upsetting can also be done in a vertical crank press or a hydraulic press. 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
7030-605: The imports and increase self-reliance, DRDO Chief called for more collaboration with the industry, private sector, research and education institutes including IITs and NITs . India's military–industrial complex has had little success and only recently private sector was allowed to enter the defence production. To expedite the development cycle of new technologies and to better fit the end user requirements, army has asked DRDO to take more army staff on deputation to be part of DRDO technology development project teams. Indian forces are using numerous indigenous technologies produced by
7125-465: 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
7220-444: 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 is not used to deform the workpiece) that is not released as heat or sound needs to be transmitted to
7315-493: 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. 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
7410-407: 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, such as the four-die device , use fluid pressure and a piston to generate force. The advantages of a hydraulic press over
7505-568: The needs of ISRO's human space mission with critical human-centric systems and technologies like space grade food, crew healthcare, radiation measurement and protection, parachutes for the safe recovery of the crew module and fire suppression system etc. Kalyani Group is developing the Advanced Towed Artillery Gun System . DRDO with Federation of Indian Chambers of Commerce & Industry (FICCI) under Advance Assessment Technology and Commercialisation Programme
7600-630: 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
7695-579: 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, then 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
7790-405: 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
7885-414: The proper thickness. Once the proper thickness is achieved the proper width is achieved via "edging". " 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
7980-444: 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 . This process is also known as precision forging . It was developed to minimize cost and waste associated with post-forging operations. Therefore,
8075-475: The same process as outlined above, except the preform is produced by the spraying deposition of metal droplets 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 greater production volume. This
8170-407: 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
8265-582: The suit and satellite recovery systems. Hyderabad-based 3D printing startup iMake with Modern Manufacturers and Kirat Mechanical Engineering from Chandigarh , Wipro 3D from Bengaluru and Global Healthcare from Delhi are 3D printing visor-based face shields which is an offshoot of the tech developed for high-altitude military parachuting . Setco from Mumbai is producing sealants developed for submarines of Indian Navy at DRDO labs for personal protection equipment. Research Centre Imarat (RCI) and Terminal Ballistics Research Laboratory (TBRL) developed
8360-421: The systems seeing rapid deployment as well as yielding significant technological benefits. Since its establishment, DRDO has created other major systems and critical technologies such as aircraft avionics, UAVs , small arms, artillery systems, EW Systems, tanks and armoured vehicles, sonar systems, command and control systems and missile systems. The Government of India has plans to overhaul and reform DRDO, and
8455-616: The tensile strength of medium strong steel alloys while providing significant weight advantages. Therefore, aluminium forged parts are mainly used in aerospace, automotive industry and many other fields of engineering especially in those fields, where highest safety standards against failure by abuse, by shock or vibratory stresses are needed. Such parts are for example pistons, chassis parts, steering components and brake parts. Commonly used alloys are AlSi1MgMn ( EN AW-6082 ) and AlZnMgCu1,5 ( EN AW-7075 ). About 80% of all aluminium forged parts are made of AlSi1MgMn. The high-strength alloy AlZnMgCu1,5
8550-422: 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. 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
8645-622: 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. There are many different kinds of forging processes available; however, they can be grouped into three main classes: Common forging processes include: roll forging, swaging , cogging , open-die forging, impression-die forging (closed die forging), press forging, cold forging, automatic hot forging and upsetting. All of
8740-514: The use of large trip hammers or power hammers that increased the amount and size of iron that could be produced and forged. 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
8835-545: 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, 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 automatic hot forging process involves feeding mill-length steel bars (typically 7 m (23 ft) long) into one end of
8930-412: The workpieces for further forging processes. Impression-die forging is also called "closed-die forging". In impression-die forging, the metal is placed in a die resembling a mold, which is attached to an 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
9025-713: Was formed in 1980, which later administered DRDO and its almost 30 laboratories and establishments (there were almost 52 labs before merging). Most of the time, the Defence Research and Development Organisation was treated as if it were a vendor and the Army Headquarters or the Air Force Headquarters were the customers. Because the Army and the Air Force themselves did not have any design or construction responsibility, they tended to treat
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