Die Shop:

Die block material arrives (raw material). Product data

sheet is used.
One copy is kept in die shop, rest copies are sent to
stores.
Next comes the handling part. To handle the raw
material, holes (lift holes) are made on four sides of the
material for handling and clamping.
Next, machining process occurs. Top & bottom,
reference points are machined.
Vernier height gauge, dividers are used.
CNC machines are used for surface machining.
Inspection is made to check the corner radii, depth,
fillet etc...
Forge shop:
Raw material is kept in the material yard.
For specified product to be made, specified material is
taken i.e., length, type of materials etc.
Using band saw cutter, billet material is cut and
kept.
Then the billet material is heated to its near value of
its melting point.
Then comes the prep forging process. Here the billet
is forged to half portion shape of product from the
die.
 Then finish forging process occurs. Here the billet is
made into complete product shape with help of die.
Both prep and finish forging process are done with
hammering operation.
For prep forging, 13T is used and for finish forging,
16T is used.
Then the billet material is sent to trimming process in
the hydraulic press.
Then it is sent to inspection procedure.
Fettling and Heat treatment:
After forging process, heat treatment process
occurs i.e., normalizing, hardening, tempering,
stress relieving, annealing.
Normalizing is done between 890-900 degree
Celsius
Hardening is at 830-840 degree Celsius. Polymer
quenching is done.
Tempering is at 530-630 degree.
Annealing is done for high carbon steel. Furnace
cooling is done. 900-920 degree is maintained.
Heat treatment is done to ensure the hardness of
the material. If the material satisfies the hardness
(BHN- Brignell Hardness Number), it is sent to
fettling DPT.
Shot blasting is done to polish the material.
 Crack detection is done to ensure no cracks are
found in the product.
After crack detection process, demagnetizing
operation is done to demagnetize the product.
Then final inspection process is made to ensure the
product is made to customer specification.
Then it is sent to dispatch.