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Full Version: Forgings, its TECHNIQUES AND MECHANISMS- Project Report
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Abstract: The term “Forging” is applied to processes in which a piece of metal is worked in a machine to the desired shape by plastic deformation of the starting stock. The energy that promotes deformation is applied by a hammer, press, up-setter or ring roller, either alone or in combination. The shape is imparted by the tools that contact the work piece and by careful control of the deformation process. A forging is produced in three distinct phases: stock preparation in the form of blooms, billets, bar or ingots; plastic deformation of the metal component to rough, close tolerance or net shape in one of the forging processes; and appropriate secondary operations
Forged metal components are used in wide range of environment where high strength and reliability are important considerations. The use of forging is to reduce material wastage and machining time, avoids complex machining operations and for mass production. Forged components find application in the automobile/automotive industry and in aerospace, aircraft, railroad, and mining equipment.
Metal forging process is governed by many factors such as friction, complexity of parts, die shape and temperature of die and billet. In this study we are going to learn about the principles of material selection, heat treatment, and the design calculations, which is involved in forging of metal
This project is a study of the forging process, forgings defects, the forging machines and their applications. In this project we also consider the manufacturing of crane wheels through the closed die forging process in which metal is plastically reshaped using dies. This involves the steps like design and material selection based on its properties. Machinery equipment’s used in forging are pneumatic hammer forging machines, furnaces, dies, band saw machines etc. Closed die forging process is used to obtain the final product in close tolerance. The furnace is the main equipment in which the billet is preheated to a temperature of 1200 degrees centigrade and then forged into required shape. It offers a high strength-to-weight ratio, toughness, and resistance to impact and fatigue.
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Monitoring and Controlling a project is the process or activities whereby the project manager tracks, reviews and revises the project activities in order to ensure the project creates the deliverables in accordance with the project objectives. Because of the unique and temporary nature of projects, they require active control. Unlike a process where the same set of activities have been performed repeatedly so that habits and expectations are stable, a project is inherently unstable. The activities are unique to the project or the sequence of activities and resources are only temporarily assigned and associated with the project and are redeployed when the project completes. Habits and patterns are not established before everything changes.

The primary results of the Monitoring and Controlling processes are the project performance reports and implementing project changes. The focus for project management is the analysis of project performance to determine whether a change is needed in the plan for the remaining project activities to achieve the project goals. In my experience, almost every project will require a change to the plan at some point in time. Traditional projects are the most stable projects because the requirements and the activities are clear and well understood. Adaptive and Extreme projects are the least stable. They require very close control and will require numerous changes - if for no other reason the project manager will need to refine the activities of later phases based upon the results of early activities.

Tools and techniques that are used by project managers to conduct the Monitoring and Controlling of a project fall into one of four general categories. The first is the collection of project performance information. Techniques supporting this category are Pulse Meetings, Variance Reports, and Program Reviews. The second category is the analysis of the project performance to determine whether a project change is needed. Techniques that are used in this category are Technical Reviews, Project Forecasting and Problem Solving. The third category is reporting on project performance. Techniques that support this activity include the use of a Project Management Information System, Management Reviews, and Dashboards. The final category is the management of project change. The technique I commonly use in this category is the maintenance of a Change Management Log. There are two areas of project management tools and techniques that closely support the Monitoring and Controlling process but are also used more broadly throughout the project lifecycle. These are important enough to justify their own page.