HG INOTTUTE OF TECHNOLOGY SUNORI MECHANICLL ENGINEERING DEPARTMENT WORASHOP MANUAL BIACK SMITHY SHOP SEMEYTER-2” (ALL BRANGDINTRODUCTION: Blackomithy or Forging i an oldest shaping process used for the producing srnall prac articles for which accuracy fe , in size is not so important tye the parts are shaped by b LL wend heating them in an open fire or hearth by the | blacksmith and shaping them through — applying compressive forces using hammer as the plastic deformation of Thus forging is defined termined Ze metals at elevated temperatures into a prede or shape using compressive forces eyerted through some means of hand hammers, small power hammers, die, press of upsetting machine, It consists essentially of changing OF altering the shape and section of metal by hammering ata temperature of about 920°C, at which the metal is entirely plastic and can be easily deformed or shaped under pressure, The shop in which the various forging operations are carried out is known as the smithy or smith’s shop Hand forging process is also known as black smithy work which is commonly employed for production of small articles using hammers on heated jobs. It is a manual controlled process even though some machinery such as power hammers can also be sometimes used. Black-smithy is, therefore, a process by which metal may be heated and shaped to its requirements by the use of blacksmith tools either by LLL 7PAOOUOREL ENT OEUA ER EEL EL EEE hand or power haniner forging by machine involves the use of forming dies and is generally employed for mass produchon of accurate articles, In drop forging, closed impression dies are used and there Is drastic Now of metal in the dies due to repeated blow or impact which compels the plastic metal to conform to the shape of the dies, Applications of forging: Almost all metals and alloys can be forged. The low and medium carbon steels are readily hot forged without difficulty, but the high-carbon and alloy steels are more difficult to forge and require greater care forging is generally carried out on carbon alloy steels, wrought iron, copper base alloys, aluminum alloys, and magnesium alloys, Stainless eels, nickel-based super alloys, and titanium are forged especially for ACTON PACE UGE, FORGEABILITY: The ease with which forging is done is called forgeability, The forgeability of a material can also be defined as the capacity of a material to undergo deformation under compression without rupture. Forgeability increases with up to a point at which a second m ferrite to austenite in steel, rowth becomes excessive, LEEOPERATION: The following are the basic operations performed by hand forging: 1. Drawing-down: Drawing is the process of stretching the stock while reducing its cross-section locally. Forging the tapered end of a cold is an example of drawing operation. 2. Upsetting: It is a process of increasing the area of cross- section of a metal piece locally, with a corresponding reduction in length. In this, only the portion to be upset is heated to forging temperature and the work is then struck at the end with a hammer. Hammering is done by the smith (student) himself, if the job is small, or by his helper, in case of big jobs, when heavy blows are required with a sledge hammer. 3. Fullering: Fullers are used for necking down a piece of work, the reduction often serving as the starting point for drawing. Fullers are made of high carbon steel in two parts, called the top and bottom fullers. The bottom tool fits in the hardie hole of the anvil. Fuller size denotes the width of the fuller edge. 4. Flattering: Flatters are the tools that are made with a perfectly flat face of about 7.5 cm square. These are used for finishing flat surfaces. A flatter of small size is known as set-hammer and is used for finishing near corners and in confined spaces. that may beS Swenlog Swans like fullers are also made of high carbon steel and are made in two parts called the lop and swages These are tised to reduce and finish to round, square or Hexagonal forms, bor this, the swages are made with Hall grooves of dimensions to suit the work © Bending: Honding of bars, flats, ete, is done to produce different types of bent shapes such as angles, ovals, didlos eth, Sharp bends as well as round bends may be made on the anvil, by choosing the appropriate place OH Eon The purpose 7 Twisting It is also one form of bending, Sometimes, it is done to increase the rigidity of the work piece, Small piece may be twisted by heating and clamping a pair of tongs on each end of the section to be twisted and applying a turning moment Larger pleces may be clamped in’ a leg view and twisted with a pair of tongs or a monkey wrench However, for uniform twist, it must be noted that the complete twisting operation must be performed. in one heating, 8, Cutting (Hot and Cold Chisels): Chisels are used to cut metals, either in hot or cold state, The cold chisel is similar to filter's chisel, except that it is longer and has a handle, A hot chisel is used for cutting hot metal and its cutting edge is long and slender when compared to cold chisel, These chisels are made of tool steel, hardened and tempered.i To remove internal stresses set-up during forge, mm, cooling, i To normalize the internal structure of the meta tii To improve machinability. d hardness jy, Toimprove mechanical properties, strength ane he ., ; ; TOOL USED: : . 3a Tongs: 3 ; The tongs are generally z used for holding work while doing a forging j operation. Various kinds of tongs are shown in Figure a) Straight-lip fluted tongs are commonly used for holoing square, circular and hexagonal bar stock b) Rivet or ring tongs are widely used for holding bolts, rivets and other work of circular section. c) Flat tongs are used for mainly for holding work of rectangular section. d) Gad tongs are used for holding general pick-up work, either straight or tapered. Flatter: it is commonly used in forging shop to give smoothness and accuracy to articles which have already been shaped by fullers and swages. Swage: . swage is used for forging work which haslll ah Niohed 4H 1H, ert OF heoranpe (He, pada sinh Wd nies A BARRED pt Ce WHE eng, Hee, Lipithsy A tis (RPL, HA MOY ve png ae with wits id WDNR GH F PI, # Meve® inne vstnchh Vike 4) hie te ke bids 1) Fate HOOPS tue puller j apy biflar i RE CHG POW ty LED don a lorypihe Yh, WG ate 8 9 WOE nolo ls wh Wt Oe Ce A VP fiber io tine i SAA Piss BO KES wtthh tg, phbliy, ie GIR Gactiifig te Wile Of thie tifa ehS wun pipe 4 HAE Vth PD bik BOOED HOR hte usher 4 4 we HY, Ve * “ pived Nene’ ine wacnter Vo tHe 0 ONO wotsnyans _ hand of Watt Sup at eat oaet £ f he ga Mex isi, GOO SO hd Cnet O4, Pi BE AAAWWRAAASE 3 Zz Z 3 Z z z z $ Z Z Z 3 Z ;| e the metal to be cut is hot or cold. A hot ehiselBe dere. y _ k in forging shop. The edge of a cold chisel is hardene na tempered with an angle of about 60°, while the edge of a hot chisel is 30° & hardening is not necessary. Hand hammers: There are two major kinds of hammers are used in hand forging: a. The hand hammer used by the smith himself and b. The sledge hammer used by the striker. Hand hammers may further be classified as (a) ball peen hammer, (b) straight peen hammer, and (c) cross peen hammer. Sledge hammers may further be classified” as (a) Double face hammer, (b) straight peen hammer, and (c) crosspeenhammer, Hammer heads are made of cast steel and, their ends are hardened and tempered. The striking face is made slightly convex. The weight of a hand hammer varies from about 0.5 to 2 kg whereas the weight of a sledge hammer varies from 4 to 10 kg. Set hammer: A set hammer generally used in forging shop is shown in Fig. It is used for finishing corners in shoulderedwork where the flatter would be inconvenient, It ls also used for drawing out the gorging job Anvil: An anvil is a most commonly used tool ina forging shop. It acts a6 a support for blacksmith’s work during hammering, The body of anvils is made of mild steel face welded on the body, but the beak or horn used for bending curves is not steel faced The round hole in the anvil is called pritchel hole is generally used for bending rods of small diameter, and as die for hot punching operations, Hardie holw (square) IM witha lies | -Prichal hole feet) * t Tail r - Swage block: f = Body pao (wiy Swage block generally used ini forging shop for mainly heading, bending, squiring, sizing and forming operations on forging jobs, It is 0.25mt, or even more wide, It may be used either flat or edgewise in its stand, ,To make a staple of mild steel rod. Material: Mild steel r08. Dimension: Length: 140mm, Diameter: amm Tools required: 4) Forge 2) Anvil 3) Tongs 4) Chisel 5) Double face hammer Procedure: 1 By given dimension measuring and marking done on the workpiece. 7. biter dimensioning drawing operation is to be done on the workpiece. 3, According to requirement taper provided on the job. 4, After tapering bending is provided on the workpiece. 5, Finally finishing given to the workpiece. Fh MAB! ST apg1, Always wear proper apron & gloves while working in the smithy shop. 2. Remove the wristwatch, ring & bangles if worn, while working. 3. Wear goggles or a face shield during operation. 4. Always use the appropriate tongs whose jaws fit the shape of the forging to avoid slipping of the work piece. 5. Check that the hand hammers & sledge hammers are securely fastened with a wedge to prevent loosening of hammer while in use. 6. Do not use hammers with damage handles. 7. Hot stock & anvil should be properly cleaned & free from scale, film or grease if any. 8. Do not use the mushroom head chisel, hammers & flatters. 9, Never touch the hot job with your hands or other parts of the body. 10. Heat the job carefully as per forgeability requirements of to the metal. 12.Hammering should be done on the red- hot job only.