Published Online:May 2026
Product Name:The IUP Journal of Mechanical Engineering
Product Type:Article
Product Code:IJME030526
DOI:10.71329/IUPJMECH/2026.19.2.37-45
Author Name:S Mugesh, S Saravanan, and P Velmurugan
Availability:YES
Subject/Domain:Engineering
Download Format:PDF
Pages:37-45
Cold forging is extensively employed in the automotive sector for manufacturing high-strength, precision components. However, achieving consistent centerline accuracy in inner race components remains a critical challenge due to processinduced variations. The paper presents a data-driven approach to enhance centerline accuracy in a 1000-ton cold forging process using Statistical Process Control (SPC) integrated with preventive maintenance strategies. Analysis of 125 production samples revealed an initial process capability index (Cpk) of 0.86, indicating marginally capable process operating near the upper specification limit. Root cause investigation identified key contributors, including die misalignment, inadequate clamping, gas spring pressure variation, and progressive tool wear. Implementation of targeted corrective actions resulted in a substantial improvement in process capability, with Cpk increasing to 1.80 and elimination of rejection. The findings demonstrate that the integration of SPC with structured maintenance practices significantly enhances process stability, reduces variability, and ensures consistent dimensional accuracy in cold forging operations.
Cold forging is a widely adopted metal forming process in the automotive industry due to its ability to produce components with high dimensional accuracy, superior surface finish, and enhanced mechanical properties.