Smithing & Forging
Smithing It is a process of performing various operations on relatively
small work pieces, heated in an open fire (hearth) and force
is applied to manipulate the metal by means of hand
hammers or small power hammers in a smithy shop.
Forging It is a process of producing those parts, which must be
heated in a closed furnace, and force is applied to
manipulate the metal by means of heavy hammers or
forging machines or presses.
.
HOT METAL
LEAF HOOK
FORGING TOOLS Anvil: Provides a support for blacksmith’s workpiece
when hammering.
-Beak is used for bending the workpieces
FULLER:
2) Fuller
• Used for Necking down a piece of work
Swage: To obtain reduced and finished to round, square or hexagonal form
- Made with half grooves of dimensions to suit the work being reduced 5) Swage
Flatter: To give smoothness and accuracy to components which have been already shaped by fullers and swages.
4) Flatter
Punch: Used for making holes in metal part when it is in forging heat.
3) Punch
Tongs: To hold the workpiece1) Flat Tong : For holding work of rectangular section2) Ring Tong : For holding work of circular section3) Gad Tong : For general pick-up, either straight or tapered
6) Flat tongs 7) Ring Tongs
8) Gad Tongs
Swage block:Used for squaring, sizing, bending operations
9) Swage block
Chisels: For cutting metals & for necking prior to
breaking. They may be hot or cold depending on the
metal to be cut is hot or cold.Chisels
Hot Chisel
a) Ball peen
b) Cross peen
c) Straight peen
Sledge Hammer
Set hammer
Hand hammers: They may be classified as a) Ball peen hammer b) Straight peen hammer c) Cross peen hammer d) Sledge hammer
Set hammer: Used for finishing corners in shouldered
work,where flatter is inconvenient.
Classification of Forging
Power forging
Work
Ram
Anvil
Upper Die
Lower Die
Fig. Steam Hammer
-Also called as an air and
steam hammer
-Operated by either steam or
compressed air
- Principle of operation is
illustrated in the sketch
- Require additional facilities
for supplying high pressure
steam or compressed air.
workLower Die
Upper Die
Roll
Board
Drop Forging (Stamping/ Die forging)
Fig. Board Hammer
- Also called as Gravity Hammer
or Board Hammer
Working:- Ram is fixed to the lower end of
the board- Board is placed between 2 rolls- Ram will be lifted, when both rolls
are pressed against the board
-Working stroke is produced when
the rolls are released.
-Process continues till operator
holds down the treadle
Smith forging operations
Most commonly used forging operations are:
1. Upsetting2. Bending3. Punching4. Drawing down5. Setting down6. Welding7. Cutting8. Fullering
UPSETTING (HEADING) 9
Upset forging operations
Process of increasing the thickness of a bar by reducing its length by end pressure.
BENDING
Curvilinear
Angular
Bending operations
Process of producing curvilinear or angular bends on a bar.
Done on the edge of the anvil face or beak or swage block
Figure 1
Figure 2
Figure 3
Punching operation
Process of producing holes by using
a hot punch over the pritchel hole of
the anvil.
Drawing down or SwagingProcess of increasing the length of a bar at the expense of its width or thickness or both.
Setting DownIt is a localized drawing down or swaging operation.
CUTTING
• Cutting-off is a form of chiseling whereby a long piece of stock is cut into several specified lengths, or a forging is separated (cut-oft) from its stock.
When cutting with chisels , the hammer blows are directed on to the chisel head, which must be slightly rounded.
WELDING• Joining process performed in the smithy shop.
FULLERING• Fullering or spreading the metal along the
length of the job is done by working separate sections.
• In this case, the axis of the job is positioned perpendicular to the width of the flat die.
Forged parts vs. cast parts• FORGED PARTS ARE STRONGER THAN CASTING• Forging refines the structure of metal by smashing up
large grain formations and closing up any cavities that may be present.
• Pieces formed by forging exhibit directional properties indicated by the flow lines .
• The original crystals typical of the cast structure are destroyed, hard films of brittle constituents or impurities are broken up or rolled in to fibers and a uniformity is established.
• In addition to those effects certain mechanical properties, particularly elongation percentage, resistance to shock and vibration are improved, and in favorable cases cracks and blow holes are welded up.