Abstracts: Forging is now a days worldwide process used to made most of component from steel alloys. Defects during forging process reduce the quality of the product and cause the rejection of the products. Our objectives of the project is to investigate the various forging defects that occur in a forging industry that causes high rejection rates in the components and describes the remedial measures that can reduce these defects. The result indicates that the rejection rate in the company was more than four percent for the particular component. The defects in the forged components include the crack, lapping, scale pits, unfilling, double stroke, overheating, head mark, trimming and quench cracks.
Forging is the process by which the metal is heated and is molded by plastic deformation by properly applying compressive force. Usually, the compression force is in the form of hammer blows using an electric hammer or a press. The forging refines the structure of the grain and improves the physical properties of the metal. With a suitable design, grain flow can be oriented in the direction of the principal stresses encountered in actual use. The grain flow is the direction of the pattern taken by the crystals during plastic deformation. Physical properties (such as strength, ductility and toughness) are much better in a forgings than in the base metal, which has randomly oriented crystals. There are many imperfections that can be considered as defects, ranging from traceable to starting materials to those caused by one of the forging processes or by the forging operations of the post. Defects can be defined as imperfections that exceed certain limits. In other words, there may be imperfections that are not classified as true "defects" because they are less than the tolerances in the applicable specifications. There are differences in the imperfections allowed on the floor surfaces and these vary depending on the material being forged. This is the area that requires special attention that will focus on this document and the corrective or control measures that must be taken to reduce the rate of rejection in the forging industry due to these imperfections.