Forging tools & Equipment

FORGING and its Types....
Forging is a process in which material is shaped by the application of localized compressive forces exerted manually or with power hammers, presses or special forging machines. The process may be carried out on materials in either hot or cold state. When forging is done cold, processes are given special names. Therefore, the term forging usually implies hot forging carried out at temperatures which are above the recrystallization temperature of the material.

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Forging tools & Equipment

Furnace or hearth: 

A black smith uses a furnace for heating the metal pieces. Furnace consists of four legs, a cast iron or steel body, iron bottom, a chimney and a blower. The main parts of forging furnace are as:

a. HEARTH: 

The iron bottom where fire is lightened is known as hearth. It is provided with fire brick lining.

b. TUYERE: 

A pipe containing from the bottom or rear of the hearth is known as tuyere. It is used to supply the air at high pressure.

c. HOOD: 

The upper part of furnace is called hood. It is made up of mild steel sheet with the fire brick inside it.

d. CHIMNEY: 

Chimney is fitted on the upper end of the hood. It is used for the purpose of easy escaping of exhaust gases and smoke.

e. WATER TANK: 

A small iron tank is attached with the hearth of the furnace. It is used for dipping purposes.

EQUIPMENT USED IN FORGING

Shovel: 

It is used to place the coal into the furnace hearth.

Blower: 

It is used to supply air at high pressure to the hearth.

Poker: 

It is a bent rod used to strike the fire. Poker is made up of mild steel.

Regulator: 

It is used to control the air supply of air to the hearth. Air supply is controlled by increasing or decreasing the passage of air.

Anvil: 

A block on which forging work is done is known as anvil. It is made up of cast iron, steel or wrought iron. It acts as a supporting device for all forging operations since it is capable of withstanding very heavy blows. The anvil is supported either on a iron base, or wooden block or mounted on the foundation. Weight of the anvil varies from 100-150Kg. It is available in many sizes and shapes. 

Common type of anvil used in forging shop has the following parts:
a. Body
b. Horn
c. Chipping block
d. Face
e. Hardie hole
f. Round hole
g. Tail
h. Stand

The centre part is known as body. The projected end is called horn. It is used for making circular jobs. A steel plate riveted on the body is called face. Most of the work is done on face. Chipping block is used for cutting purposes. Holes are used for chisels or punches. At the bottom four legs are attached.

Hammer: 

Hammers are used as striking tools. These are classified as:
a. Hand hammer.
b. Sledge hammer
c. Power hammer

Hand hammer is light in weight used by the smith himself. 
Sledge hammer is heavier in weight and is used by the smith’s helper. All the hammers are divided into four parts namely pean, eye, cheeks and face. Hand hammers are of four types based on shape of the pean. If the pean is along the axis of the handle then it is straight pean hammer when the pean is across the axis of handle then it is called cross pean hammer. In case shape of the pean is same as shape of the face then it is double ended. If the shape of the pean is spherical then it is ball pean hammer. The weight of hand hammer varies from 1-2Kg and that of sledge hammer is 3-8Kg. 

When the quantity of jobs to be produced is more, power hammers are used. Commonly used hammers are spring hammers, pneumatic hammers, steam hammers and drop hammers. 
Power hammers are generally driven by electrical power. The job to be produced is placed on the anvil of the hammer. with the help of lever the weight is allowed to fall on the job. The factors which influence the working of the hammer are:
• Size and shape of the job
• Falling weight of the hammer
• Height of falling weight

Tongs: 

Tongs are used for holding and turning hot metal pieces. Depending upon their use, tongs are classified into many types. All types of tongs have similar construction except the mouth. A tong has two legs riveted from a suitable place. These are made up of mild steel. It is made in two pieces and both the pieces are joined by hinges. The length of the tongs varies from 12” to 18”. It is classified based on the shape of the mouth of the tongs.

Chisels: 

Chisels are used for cutting metal pieces in hot and cold state. Chisels are divided into following categories:
a. Hot chisel
b. Cold chisel
c. Hardie set
Hot chisel is used to cut the metal in hot state and cold chisel to cut the material in cold state. Main difference between these chisels is the cutting angle. In hot chisel cutting angle is 30 degree and in case of cold chisel 60 degree. A hardie set consists of three parts:
a. Shank
b. Body
c. Cutting edge

The shank is fitted into the hardie hole in the anvil. Chisels and the hardie set are made from carbon sheets. It is hardened upto the desired level with proper tempering.

Punches and drifts: 

Punches are made up of high carbon steel and are used for making rough holes in hot metal pieces. Punches are available in different sizes but have a common shape. A drift is a large sized punch used to enlarge a hole.

Flatters: 

As indicated by name, flatters are used to flatten the work piece. It has a plane face joined with a straight shank. It is held in a wire. The material of the flatter is high carbon steel. The body of a flatter is square in cross section.

Fullers: 

Fullers are used for grooving and drawing. These are made in two pieces (lower and upper). Lower part is mounted on the anvil and the upper is held in hand from a wire handle. These are made from high carbon steel and medium carbon steel. These are for hot work only.

Swages: 

Swages are used for giving various shapes to the work pieces. These are made up of high carbon steel and are used in two pieces as in case of fullers.

Swage block: 

It is a cast iron or cast steel rectangular block having a number of holes in it. Holes are made in different sizes and shapes. Its outer sides are also made in sectional forms to receive various types of jobs. It is always plane on a cast iron frame.

Set hammers: 

Set hammers have similar shapes as that of flatters. These are used for making the surface plane, forming and making corners. It is made of tool steel. The job is supported on the anvil and set hammer is hammered on it.

Clamping vice: 

Leg vice is only clamping device used in smithy shop. It is mounted with the table or wooden base. It consists of two jaws, a spring and a leg. Hot work pieces are clamped in it while working.

Bick iron: 

It is also made of tool steel and it is hardened. It’s one portion is similar to the horn of the anvil and a tapered tail on the other side. Due to a taper shank it is fitted in the anvil. 

PRECAUTIONS WHILE USING FORGING TOOLS AND EQUIPMENT

The following points must be kept in mind while working with the forging tools:
1. Hearth should be lightened is proper way.
2. Hammering should not be done in lazy mood.
3. Heavy blows should not be given on the tail of the anvil.
4. Hammers should have proper handle length.
5. Length of the tong should be kept between 15” to 18”. The tong should be kept cool while working with it.
6. Blunt chisels should not be used in the forging shop.
7. Mushroom should not remain on the face of the flatter, punch or chisel.
8. Never use fullers and swages for cold metal.
9. While working on furnace, keep the fire small but deep.
10. Do not let the fire burn hollow.
11. Keep the fire clear from clinkers, particularly while welding.
12. Do not add fresh coke on the top of the fire, put it at the side and pull in later when required.