Gates also leave gate vestige or a visual indication that the part was gated—even if it is subtle.

That’s why we recommend letting your supplier know about any aesthetic and functional
requirements and defining where not to gate.

1b)
Economic Consideration in Material Selection Section
In engineering practice there are other important criteria that must be considered in the
development of a marketable product. Some of these are economic in nature, which, to some
degree, are unrelated to scientific principles and engineering practice, and yet are significant if a
product is to be competitive in the commercial marketplace. It is essential for the engineer to
know about and understand economic issues simply because the company/ institution for which
he or she works must realize a profit from the products it manufactures. Materials engineering
decisions have economic consequences with regard to both material and production costs. There
are three factors over which the materials engineer has control and that affect the cost of a
product; they are
(1) component design,
(2) the material(s)
(3) the manufacturing technique(s) that are employed.
These factors are interrelated in that component design may affect which material is used, and
both component design and the material used will influence the choice of manufacturing
technique(s). Economic considerations for each of these factors is now briefly discussed. Lecture
five Selection of Engineering Materials for Design Economic Considerations in Material
Selection Dr Khulood I. D.
1- Component Design: Some fraction of the cost of a component is associated with its design. In
this context, component design is the specification of size, shape, and configuration, which will
affect in-service component performance. For example, if mechanical forces are present, then
stress analyses may be required. Detailed drawings of the component must be prepared;
computers are normally employed, using software that has been generated for this specific
function. It is often the case that a single component is part of a complex device or system
consisting of a large number of components (i.e., the television, automobile, DVD
player/recorder, etc.). Thus, design must take into consideration each component’s contribution
to the efficient operation of the complete system.
2- Materials: In terms of economics, we want to select the material or materials with the
appropriate combination(s) of properties that are the least expensive. Once a family of materials
has been selected that satisfy the design constraints, cost comparisons of the various candidate
materials may be made on the basis of cost per part. Material price is usually quoted per unit
mass. In addition, during manufacturing there ordinarily is some unavoidable material waste,
which should also be taken into account in these computations.
3- Manufacturing Techniques: As already stated, the choice of manufacturing process will be
influenced by both the material selected and part design. The entire manufacturing process will
normally consist of primary and secondary operations. Primary operations are those that convert
the raw material into a recognizable part (i.e., casting, plastic forming, powder compaction,
molding, etc.), whereas secondary ones are those subsequently employed to produce the finished
part (i.e., heat treatments, welding, grinding, drilling, painting, decorating). Lecture five
Selection of Engineering Materials for Design Economic Considerations in Material Selection Dr
Khulood I. D. The major cost considerations for these processes include capital equipment,
tooling, labor, repairs, machine downtime, and waste. Of course, within this cost analysis, rate of
production is an important consideration. If this particular part is one component of a system,
then assembly costs must also be addressed. Finally, there will undoubtedly be costs associated
with inspection and packaging of the final product. As a sidelight, there are also other factors not
directly related to design, material, or manufacturing that figure into the product selling price.
These factors include labor fringe benefits, supervisory and management labor, research and
development, property and rent, insurance, profit, taxes, and so on.

8a)
The first and most significant step in the die design is the selection of suitable parting line.
Parting line is the plane where the two die halves meet along the forging. The selection and
location of parting line affect many parameters like load and energy requirement, grain flow,
amount of draft, die sinking, trimming operation, cost of the die, defect formation, die wear and
die life. The basic criteria for selection of parting line is to avoid deep impressions, to avoid side
thrust, favourable grain flow, maximum periphery Even after fulfillment of these basic criteria,
still there is lot of scope for variation in the selection of parting line. The selection of correct
parting line reflects the skill and knowledge of die designer.
The first step in designing forging dies is selection of parting line. Selection of parting line
affects the load, effective stress and grain flow in the component. In the current study three
different parting lines are selected. The three different paring lines are named as top parting line,
bottom parting line and central parting line which are shown in the Figure.1

After selection of parting line various allowances like finish allowance, draft allowance, fillet
and corner radii are added to the component on basis of IS-3469[11]. A three stage forging
process which includes an upsetter, blocker and finisher is incorporated. Now the flash is
designed based on Neuberger & Mockel’s equations 1 and 2. The thickness and width of flash
are 2.4mm and 7.8mm respectively.
Flash thickness t (mm) = 0.89√W – 0.017W + 1.13----------- (1)
Flash width w (mm) = t (3 + 1.2 x e-1.09W) -------------------- (2)
Where W is weight of forging in kg

The finisher is obtained by scaling the forging by 1.05 times to compensate the contraction
which occurs during the cooling of the component from forging temperature to room
temperature. The blocker is designed from finisher by reducing each side along the width by
0.3mm and increasing the depth, keeping the volume constant. A cup type upsetter is designed,
so that the upsetted billet will sit in the blocker bottom die. For this the cup radius of the upsetter
bottom die is kept 0.3mm less than the minimum radius of the blocker. The cross sectional views
of upsetter, blocker and finisher die sets with top parting line are shown in the figure 2. Similarly
two die sets with bottom parting line and central parting line are designed.

For inverted dies a different approach is used as the placement of the billet will be difficult in
such type of dies. Blocker and finisher dies are designed in the same fashion with a difference
that the impression is cut completely in the top die instead of bottom dies. The bottom die of the
upsetter is kept same as that in the previous case but the top die is given the shape of the blocker
bottom die, and the width vise dimensions are reduced by 0.6mm.The cross sectional views of
upsetter, blocker and finisher die sets with inverted dies are shown in the Figure3.