APPLICATION OF FORGINGS AND THEIR IMPORTANCE

JAV Forgings & Engineering Pvt. Ltd. is India’s leading steel forging manufacturer and supplier of a diverse range of products. Our forging product list includes high quality of Flanges, Tube sheets, Rings and Shafts, Spectacle Blinds, Stub ends, Ring-joint gaskets and Self-reinforced nozzles.

Here are some applications of Forgings:

OIL& GAS PLANTS:

JAV Forgings & EngineeringPvt. Ltd. has been manufacturing various forged fittings to oil & gas developing equipment manufacturers more than 10 years. Worked as the fuction of connection, they require prefect assembling and could bear high pressure. Such pressure will be tested by air or water with forging process.

POWERPLANTS:

A forging for power-plant industry is priority business segment for OMZ-Special Steels. Key products of this segment are turbine generator rotor shafts, steam turbine rotor shafts, hydraulic shafts and forgings for hydropower industry, forgings for gas transporting plants and gas turbines, forgings for shafts and components of power plant equipment etc.

AUTOMOBILES:
Strength, reliability and economy are the desired characteristics for application in automobile industry. Forged components possess these characteristics, thus making forged parts suitable for application in automobile industry. Forged components possess good shock absorbing capacity and therefore are found at points of shock and stress such as axle beams, wheel spindles, shafts, kingpin, torsion bars, ball studs, pitman arms, idler arms, and steering arms.

Forged parts also find application in the power train, where connecting rods, drive shafts, transmission shafts, differential gears, clutch hubs and yokes are often forged.

VALVES AND FITTINGS:

Forgings are often associated with the high pressure applications in the valve and fitting industry because of their superior mechanical properties and freedom from porosity. Corrosion and heat-resistant materials are generally used for valve bodies and stems, flanges, tees, saddles, elbow reducers, and other fittings.

HAND TOOLS & HARDWARE

Hand tools and hardware have been traditionally forged as the mark of quality. Wrenches, pliers, hammers, garden tools, sledges, wire-rope clips, sockets, nut and bolts, hooks, turnbuckles are common examples of forged hand tools and hardware. Forged components find application in surgical and dental instruments too.

MACHINERY & EQUIPMENT

Forgings find application in off-highway and heavy construction equipment, mining equipment, and material handling applications owing to their high strength, toughness and machinability. Equipment and machinery used in steel, paper, textile, power generation and transmission, chemical and refinery industries also use forged components.

DEFENCE AND ARMED FORCES

Forgedcomponents are found in almost every implement of defense, from rifle triggers to nuclear submarine drive shaft, all comprise forged parts. Missiles, heavy tanks, armoured carriers, shells and other heavy weapons are common defense-related applications of forged components.

AEROSPACE
For aerospace application, high strength-to-weight ratio and structural reliability are the most significant properties required. Performance, range, and payload capabilities of aircraft highly depend on these properties. Commercial jets, helicopters, piston-engine planes, military aircraft and spacecraft widely use forgings. Forgings component are used as and in bulkheads, wing roots and spars, engine mounts, hinges,  brackets, shafts, beams, landing gear cylinders and struts, wheels, brake carriers and arresting hooks. In jet turbine engines, super alloys (iron-base nickel-base and cobalt-base) are forged into components such as buckets, discs, blades, couplings, rings, manifolds, chambers and shafts.

Products Produced By Forging Process

Various automobile parts are produced by forging process. The following are few products manufactured by JAV Forgings & Engineering Pvt. Ltd. in Faridabad, Haryana India. Our forgingproducts include high quality of Stainless Steel, Mild Steel, Alloy Steel, Carbon Steel, Duplex, Super Duplex, Inconel, Hastelloy and Monel

1. FLANGES – JAV Forgings produce forging flanges. A flange is the process of connecting pipes, pumps, valves and other equipment to form a piping system. It also provides easy cleaning, modification or inspection. Flanges are usually welded or screwed. Flange joints are made by bolting together two flanges with a gasket between them to provide a seal. JAV Forgings & Engineering Pvt.Ltd. manufactures all types of flanges like Weld Neck Flange, Orifice Flange, Slip-On Flange, Blind Flange, Socket Weld Flange, Threaded Flange, Lap Joint Flange and Girth Flange.

2. TUBE SHEETS – JAV Forgings & EngineeringPvt. Ltd. is a tube sheet manufacturer in Faridabad, Haryana India. Forging Tube Sheets usually made from a round flat metal plate or sheet with holes drilled to accept the tubes or pipes in an accurate location and pattern relative to one another. The tube sheets are used to support and isolate tubes in heat exchangers and boilers or to support filter elements. The tube sheets can be supplied in fully machined and drilled condition. The tube sheets are manufactured as per customer’s requirements.

3. FORGED RINGS and FLATS – JAV Forgings and Engineering Pvt. Ltd. manufacture Rings and Flats. The different varieties of Forged Rings can be produced like Drip Rings and Flushing Rings.

Forged Flats are of different sizes, are commonly manufactured for modern industry for various applications, such as parts for machine tools, aerospace applications, turbines and pressure vessels.

A wide range of forged rings and flats are available in different diameters, weights and thickness meant for various purposes.

4. SHAFTS AND ROUNDS – JAV Forgings & Engineering Pvt. Ltd. manufactures a wide range of round bar and roll shaft like piston rod, intermediate shaft, cross head pin, propeller shaft, main journal, crank shaft etc. for various purposes, including industrial engineering, paper mill, sugar industry, textile mill, automobiles and general mechanical engineering purposes.

The different varieties of Crank Shafts are produced by like Stainless Steel Crank Shafts, Mild Steel Crank Shafts, Alloy Steel Crank Shafts, Carbon Steel Crank Shafts, Duplex Crank Shafts, Super Duplex Crank Shafts, Inconel Crank Shafts, Hastelloy Crank Shafts and Monel Crank Shafts.

5. SPECTACLE BLIND – A spectacle blind is a safety device used to isolate a part of line or piece of equipment when the line or equipment needs to be inspected or removed from service. It is completely different than a valve in that the blind is a permanent or long-term isolation device. A spectacleblind is machined from a single piece of metal that is move match the pipe size, fit between two pipe flanges and needs an additional gasket during installation.

6. STUB ENDS – JAV Forgings & EngineeringPvt. Ltd. is a Stub End manufacturer in Faridabad, Haryana India. Stub ends are installed in pairs and mated along with two lap joint flanges. The surface of the stub end includes a phonographic serrated gasket surface that prevents leakage at the joint  using stubends allows sections of the line to be opened for cleaning, inspection or quick replacement etc, without the need to re-weld.

7. RING JOINT GASKETS – JAV Forgings and Engineering Pvt. Ltd. is a Ring Joint Gaskets manufacturer in Faridabad, Haryana India. Ring JointGaskets are produced from different solid metal types. They are used to stand high pressure and temperatures and they are used where corrosive agents are present. These gaskets are obtained by mechanical working from forged or laminated metals in one single piece. They are used in production and refining process of oil and chemical industries.

8. SELF-REINFORCED NOZZLES – JAV Forgings and EngineeringPvt. Ltd. is a Self-Reinforced Nozzles manufacturer. Self-reinforced nozzles are nozzle necks specifically designed and forged with an extra heavy wall, attached to the thinner end of the piping. Basically, in operations of heavy pressure, a self-reinforced nozzle head cuts out the burden of reinforcing the nozzle or piping with further plating or added forgings, making for a more cost-effective nonetheless structurally sound solution.

Stub Ends are fittings used in place of welded Flanges

JAV Forgings & Engineering Private Limited in Faridabad Haryana India discusses Stub Ends are fittings employed in place of welded flanges wherever rotating back up flanges are desired. They are also referred to as Lap Joints and Vanstone flared Laps. JAV Forgings & Engineering Pvt. Ltd. is India’s leading steel forging manufacturer and supplier of a diverse range of products. Our forging product list includes high quality of Flanges, Tube sheets, Rings and Shafts, Spectacle Blinds, Stub ends, Ring-joint gaskets and Self-reinforced nozzles.

A rotating back up flange seats itself against the back surface of the Stub end. Once bolts are added, the clamping action of the bolts presses the rotating back up flange against the back of the Stub end. The gasket surface of the Stub end then presses against a gasket and another gasket surface provides joints like standard flange joints. The seal is formed by the gasket surface of the stub end alone, the flange only provides the clamping pressure on the joint.

A stub end and a lap joint flange can be used together as an alternative way to make a flanged connection than welding neck flanges.

The two devices to be combined, in this case, are:

• The stub end, which is essentially a piece of pipe, with one end flared outwards and the other prepared to be welded to a pipe of the same bore size (NPS = nominal pipe size), material and wall thickness. The most widely used fabrication tool for stub ends is the flaring machine, which is able to flare the end of the pipe and then cuts it to length.

• A Lap Joint Flange, which is used to actually bolt the two lengths of pipe together.

BENEFITS OF LAP JOINT STUB ENDS

The use of stub ends has these two advantages:

·        Reduces the overall cost of the flanged joint

·        Facilitates the installation of the flange

STUB END TYPES

Stub ends are available in three different types, named “Type A”, “Type B” and “Type C”:

• The first type (A) is manufactured and machined to match standard lap joint backing flange (the two products have to be used in combination). The mating surfaces have an identical profile to permit a smooth loading of the flare face
• Stub ends type B are have to be used with standard slip-on flanges
• Type C stub ends can be used either with lap joint or slip-on flanges and are manufactured from pipes.

SHORT/LONG PATTERN STUB ENDS (ASA/MSS)

Stub ends are available in two different patterns:

• the short pattern, called MSS-A stub ends
• the long pattern, called ASA-A stub ends (or ANSI length stub end)

Short pattern (MSS) and long pattern stub ends (ASA)

STUB END FINISH

Stub ends can be ordered with different ends finishing:

• Beveled Ends
• Squared Ends
• Flanged Ends
• Grooved Ends
• Threaded Ends (Male Only)

Greatest Moments in Details of Flanges - Types of Flanges History

Flanges are projecting or internal components used to support mechanical parts. Most often, they're rims, and that they are put in place to strengthen the mechanical part or provide a way of attaching that part to another part or surface. A simple pipe flange would be a slip-on or threaded flange that fits around one end of a pipe and provides a way to bolt that pipe to a wall or fixture. Such a flange would be a circular component with a central means of holding the pipe and bolt holes placed evenly in the outer rim.

Flangestypes

As already described, the most used flange types ASME b16.5 are: Welding Neck, Slip On, Socket Weld, Lap Joint, Threaded and Blind flange. Below you'll find a short description and definition of every type, completed with a detailed image.

Most common flange types

WeldingNeck Flange

Welding Neck Flanges are easy to recognize at the long tapered hub that goes gradually over to the wall thickness from a pipe or fitting. The long tapered hub provides a very important reinforcement to be used in many applications involving high pressure, sub-zero and / or elevated temperatures. The graceful transition from projection thickness to pipe or fitting wall thickness affected by the taper is extremely helpful, under conditions of repeated bending, caused by line expansion or other variable forces. These flanges are bored to match the inside diameter of the sex pipe or fitting therefore there will be no restriction of product flow. This prevents turbulence at the joint and reduces erosion. They also give excellent stress distribution through the tapered hub and are simply radio graphed for flaw detection.

This flange type will be welded to a pipe or fitting with a single full penetration, V weld (Butt-weld).

Weld Neck Flange

1. Weld Neck flange 2. Butt-Weld
3. Pipe or Fitting

SlipOn flange

The calculated strength from a Slip On flange under internal pressure is of the order of two-thirds that of Welding Neck flanges, and their life under fatigue is about one-third that of the latter.

The connection with the pipe is done with 2 fillet welds, as well at the outside as also at the inside of the flange. The X measure on the image, are approximately:
Wall thickness of pipe + 3 mm. This space is necessary, to do not damage the flange face, during the welding process.

A disadvantage of the flange is, that principle always firstly a pipe must be welded and then just a fitting. A combination of flange and elbow or flange and tee is not possible, because named fittings have not a straight end, that complete slid in the Slip on flange.

Slip On Flange

1. Slip On flange 2. Filled weld outside
3. Filled weld inside 4. Pipe

SocketWeld flange

Socket Weld flanges were initially developed for use on small-size high pressure piping. Their static strength is equal to Slip On flanges, but their fatigue strength 50% greater than double-welded Slip On flanges.

The connection with the pipe is done with one fillet weld, at the outside of the flange. But before welding, a space must be created between flange or fitting and pipe. The purpose for the bottoming clearance in a Socket Weld is usually to reduce the residual stress at the root of the weld that could occur during solidification of the weld metal.

The disadvantage of this flange is right the gap, that must be made. By corrosive products, and mainly in stainless steel pipe systems, the crack between pipe and flange can give corrosion problems.

Socket Weld Flange

1. Socket Weld flange 2. Filled Weld 3. Pipe
X = Expansion gap

LapJoint flange

Lap Joint Flanges have all the same common dimensions as any other flange named on this page however it does not have a raised face, they used in conjunction with a "Lap Joint Stub End".

These flanges are nearly identical to a Slip On flange with the exception of a radius at the intersection of the flange face and the bore to accommodate the flanged portion of the Stub End.

Their pressure-holding ability is little, if any, better than that of Slip On flanges and the fatigue life for the assembly is only one tenth that of WeldingNeck flanges. They may be used at all pressures and are available in a full size range. Lap Joint flanges have certain special advantages:

• Freedom to swivel around the pipe facilitates the lining up of opposing flange bolt holes.
• Lack of contact with the fluid in the pipe often permits the use of inexpensive carbon steel flanges with corrosion resistant pipe.
• In systems which erode or corrode quickly, the flanges may be salvaged for re-use.

Lap Joint Flange

1. Lap Joint flange 2. Stub End
3. Butt Weld 4. Pipe or Fitting

Threadedflange

Threaded Flanges are used for special circumstances with their main advantage being that they can be attached to the pipe without welding. Sometimes a seal weld is also used in conjunction with the threaded connection. Although still available in most sizes and pressure ratings, screwed fittings today are used almost exclusively in smaller pipe sizes.

A threaded flange or fitting is not suitable for a pipe system with thin wall thickness, because cutting thread on a pipe is not possible. Thus, thicker wall thickness must be chosen...what is thicker?

Threaded Flange

1. Threaded flange 2. Thread 3. Pipe or Fitting

BlindFlange

Blind Flanges are manufactured without a bore and used to blank off the ends of piping, Valves and pressure vessel openings. From the standpoint of internal pressure and bolt loading, blind flanges, particularly in the larger sizes, are the most highly stressed flange types. However, most of these stresses are bending types near the center, and since there is no standard inside diameter, these flanges are suitable for higher pressure temperature applications.

Details of Blind flange

1. Blind flange 2. Stud Bolt 3. Gasket 4. Other flange

Never Mess With The Difference In Cold, Warm, And Hot Forging And Here's The Reasons Why.

While the hot, glowing material is closely associated with the forging method this is not always the case. JAV Forgings & Engineering Private Limited in Faridabad Haryana India discusses the differences between forging at cold, warm, and hot temperatures and how every of these affects the finished product including high quality forgings of Mild Steel, Carbon Steel, Alloy Steel, Stainless Steel, Duplex, Super Duplex, Hastelloy, Monel, Inconel, Die-Steel and Lowtemperature Carbon Steel. JAV Forgings & Engineering Pvt. Ltd. is India’s leading steel forging manufacturer and supplier of a diverse range of products. Our forging product list includes high quality of Flanges,Tube sheets, Rings and Shafts, Spectacle Blinds, Stub ends, Ring-joint gasketsand Self-reinforced nozzles.

By forging at totally different temperatures there are distinctive benefits that can be achieved while forging working. Forging forming of metals according to temperature can be divided into cold deformation (cold forging), warm deformation (warm forging) and thermal deformation (hot forging).

1) Cold forging: refers to blanks processed below the re-crystallization temperature.
Cold forging is of high dimensional accuracy, good surface roughness, good operating conditions and high production efficiency. Therefore cold forging can replace machining sometimes. Cold forging can build metal reinforcement, improve the strength of parts. So it is applicable to aluminum and plastic parts alloy, copper and alloys, low carbon steel, medium carbon steel, low alloy steel which the deformation resistance is small under room temperature. But when cold plasticity, metal deformation resistance is big, with poor plasticity, and contains accumulation of residual internal stress, needs to be continue deformation after intermediate annealing. 

2) Warm forging: forging processed around the re-crystallization temperature.
Warm forging process is to obtain precision forgings. The warm forging can improve the precision quality of forgings, at the same time, do not have the forming force as same as cold forging. Warm forging is applicable to complicated shape of small medium carbon steel precision die forgings.

3) Hot forging: deformation temperature above the re-crystallization temperature.

In the deformation process, softening and work hardening coexist at the same time, but soften can completely overcome the effect of strain hardening, and after deformation, metal will have shaft fine grained organizations such as re-crystallization, this deformation is called thermal deformation. All these processes open die forging, hot die forging, hot rolling, heat shock, hot extrusion, belong to the thermal deformation. This is one of the most widely used types of forging process.