ME1071: Manufacturing Technology

Semester: 2

Familiarization with Smith Forging

By

Index No. Name Marks

220695E Wickramage Y.N

Date of commencement 09/02/2024

Date of submission 23/02/2024

Instructors’ name and affiliation

Mr. N.D.A.
Department of Mechanical Engineering, University of Moratuwa
Wickramasinghe

Department of Mechanical Engineering

University of Moratuwa
Sri Lanka
Table of Contents
Table of Contents ................................................................................................................... 1

1 Introduction ........................................................................................................................ 2

2 Part 1 .................................................................................................................................. 2

3 Part 2 .................................................................................................................................. 4

4 Part 3 .................................................................................................................................. 5

5 References .......................................................................................................................... 6

1
1 Introduction
Forging is one of the oldest metalworking processes in human history. In forging there is no
removal of the material, but using plastic deformation in metals smiths shape the materials used
to a desired shape.

In early days man used stones and fire to do the forging but with time many techniques and
tools were introduced. Such as Heath, anvil, hammers, tongs etc.

Forging has 2 categories, and they are Hot and Cold forging. They are divided based on the
heat they use.

Forging can be used to create tools such as buckets, rings, punches, nuts, bolts and domestic
tools like knives and machetes.

2 Part 1

❖ Making the hexagonal Bolt.

1. First light up the furnace using charcoal and industrial type
blower and one end of the metal bar was heated and hold it
vertically using a tong on the anvil and hit the cold end with the
hammer. This is called as upsetting.

[1]
2. The process is repeated until we get the desired diameter at the
end of the bar. And the bar should hold vertically while
hammering.

2
 3. After that, put it into the Hardie hole and flattered the head by
hammering it.

4. Then the bolt head was heated again and hammered to get the
desired hexagonal shape. Then the bolt was cooled using water.

❖ Making the circular ring from a straight metal rod.

1. first the metal rod was bent into a circular shape using the
anvil and hammer this process also called cold forging.
this was done using the circular part of the anvil and
handheld hammer.

2. The two edges should overlap each other once the two ends
have been heated and hammered.
3. Then the joint should be welded it’s called forge welding.
4.To start, we covered the joint with clay since heating
produces ferrous oxide, which can reduce the welding's
strength.

3
 5. After that, we placed the workpiece inside the furnace
while holding it with tongs. We added some sand after
some time and watched.
6. Then we take the ring out when the ring starts to emit
sparks. This means that the ring is at over 800 Celsius.
7. Safety goggles and hand gloves must be put on before doing
the heating in this process.
8. Then ring was cooled using water.

3 Part 2
Safety precautions followed in a blacksmith shop.

• Do not wear loose fitting garments, gloves, jewellery, watches, ties,

ID badges or anything else dangling that might get caught in a piece
of moving equipment. Long hair should be secured for student
safety. [2]
• Metals can be hot even they are not red.
• Move around the workshop responsibly and refrain from interfering
with the person performing the operation as this could endanger
both you and the others.
• The flow of the processes can be quick. As an example, when you
heat the metal piece, you need to the shaping or welding process
quickly before it’s become cold. So, Place the required tools in a

4
 convenient location for easy access. Otherwise, you risk hurting
yourself.
• Tong must be used to hold the hot workpiece.
• Pay attention to the work you are doing.

• Keep a fire extinguisher and bucket of water next to the forge at all
times [2]
Different type of defects observes while during manual forging.

• Surface cracking: It happens when low temperatures during the

forging process cause the metal to break. The solution is to work at a
higher temperature. [3]
• Unfilled section: As the name implies, this defect is when
sections of the product remain unfilled. It can occur for a few
different reasons. Poor die design, improper technique, insufficient
heating, and lack of raw material are the most common culprits.
You can eliminate or reduce instances of this defect by improving
the die design, ramping up the heat, and using more material. [3]
• Cold shuts: Small fissures at corners are part of the cold shut. These
flaws result from the forging die's poor design. Additionally, the forging
product's sharp corners and excessive chilling are to blame. To
eliminate these flaws, the die's fillet radius needs to be widened.[4]
• Die shifts: An improper alignment of the upper and lower dies results
in die shift. The forged result does not obtain the correct dimensions
when these two dies are not correctly aligned. This defect can be
removed by proper alignment. It can be done by provide half notch on
upper die and half on lower die so at the time of alignment, both these
notches will match.[4]

4 Part 3

Process of fabricating a chisel.

1. Grab the steel flat bar. Using a rolling mill, roll it to the necessary chisel
thickness, then heat one end of the specimen in a furnace.

5
 2. Take the workpiece out of the furnace using a tong and put it on the
anvil and hammer it until the heated end is flat. Repeat this process until
you get a better shar flat edge.
3. Then it was put into water for cooling.
4. Then the flat edge was filled until the flat edge is closed to chisel.
to do that it should be clamped on a bench vice.
5. After cleaning the shaped end, the workpiece was placed back into the
furnace and heated to 800 degrees Celsius in order to temper it.
6. After the workpiece was removed and allowed to cool in the air, notice
how the colour changed. When the workpiece was submerged in water,
the steel's structure changed from BCC to FCC and remained in FCC as a
result of this procedure.

5 References
[1]J. Stokes, Agricultural engineering in development , . Food , 1992. Available:
https://doi.org/https://fao.org/3/ah637e/AH637E00.htm#Contents. [1]J. Stokes,
Agricultural engineering in development , . Food , 1992. Available:
https://doi.org/https://fao.org/3/ah637e/AH637E00.htm#Contents.

[2]"15 Most Important Safety Rules for Blacksmithing", Forgingworld, 9 Sep. 2021.
Available: https://forgingworld.com/15-most-important-safety-rules-for-blacksmithing/.

[3]"The Most Common Types of Forging Defects", Controlsystemsdesign, 24 Nov. 2021.

Available: https://controlsystemsdesign.com/blog/the-most-common-types-of-forging-
defects/.

[4]"Common Defects of Steel Forgings", Steelforging, 17 May. 2018. Available:

https://steelforging.org/common-defects-of-steel-forgings/.