Design Development and Fabrication of Preheating Chamber for Upset Forging Prof. Tusharkumar Raut Assistant Professor, Department of Mechanical Engineering. Vidyavardhini College of Engineering and Technology, Vasai Maharashtra, India Mittal H. Gohil Student, Department of Mechanical Engineering Vidyavardhini’s College of Engineering and Technology, Vasai Maharashtra, India Prasad D. Bangar Student, Department of Mechanical Engineering Vidyavardhini’s College of Engineering and Technology, Vasai Maharashtra, India Durgesh G. Gavaskar Student, Department of Mechanical Engineering Vidyavardhini’s College of Engineering and Technology, Vasai Maharashtra, India Nachiket P. Vaze Student, Department of Mechanical Engineering Vidyavardhini’s College of Engineering and Technology, Vasai Maharashtra, India Abstract - Forging is the process of forming the metal piece into the desired shape. This process is widely used in the industries for obtaining the desired shape of the metal. From developing simple shapes in earlier centuries with the simple hammers and anvil to developing complex shapes in the current times, there is a vast advancement in the forging process. Many types of forging processes are used in the industries such as impression die forging, cold forging, open die forging, etc. Most of the processes are carried out at 2300°F and more. A heating furnace is required for heating the metal piece to achieve the required temperature. For heating the metal pieces, we have designed and developed the direct resistance heating chamber. Keywords - Resistance heating, heating coil, helical coil, insulation. 1. INTRODUCTION Forging is the process of forming the metal piece into the desired shape. This process is widely used in the industries for obtaining the desired shape of the metal. The properties generated in the product by the process, such as acceptable dimensional accuracy, higher strength to weight ratio, superior microstructure, etc., make the forging process attractive. Other attributes such as faster processing and low material wastage, push down the cost of production of complex-shaped parts. Upset forging is used to increase the thickness or the bar’s diameter and hence reduce its length. This type of method is only used in some of the cases such as in forming the bolt head, etc. In this process, the area which is to be upset is heated locally and the rest of the area is quenched in water so that the other area does not get affected by the process. This type of process is done very carefully and it is kept in mind that the other part of the material does not get bent or deformed. For heating, the metal rods induction machines are used in the industries. The setup of these machines is complex to understand, initial as well as the maintenance cost is also high and the power consumed is also higher. This setup will overcome these drawbacks of the induction machines. This paper proposes the setup of the resistance heating chamber which has simple operating conditions, lower and affordable rates with less power consumption. 2. LITERATURE REVIEW In recent times, as we know that electricity is one of the major sources of available energy. So, electric-based process heating systems are producing methods that use electricity as its input source to produce or transform the product through the heat produced by this process. [1] An electric-based heating system is used in industry as they are controllable, clean, and efficient. In some cases, this system is selected for their unique technical capabilities while for some electricity or other fuel price is the deciding factor. So, now new systems and equipment must be made based on this system. [1] A. Resistance Heating: Resistance heating process is one of the simplest electric-based methods for heating of metals and non- metals. This process gives efficiency close to 100% and the operating temperature can exceed 3600°F. There are two basic types of this process; a) Direct Resistance Heating b) Indirect Resistance Heating Many different applications are there where resistance heating is used. These same operations can also be carried out by a variety of fuel-based processes as well International Journal of Engineering Research & Technology (IJERT) ISSN: 2278-0181 Published by, www.ijert.org NTASU - 2020 Conference Proceedings Volume 9, Issue 3 Special Issue - 2021 622