CONTENTS

• Introduction
• Producing the hexagonal bolt head and circular ring
• General safety precautions were followed in a blacksmith shop and defects observed during
manual forging
• The Process of Fabricating a chisel
• References

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INTRODUCTION

Metals are molded and molded utilizing compressive forces during the forging process. These
forces can be applied by rolling, pressing, or hammering. Processes for forging come in various varieties.
By the temperature of the metal being worked with, cold forging, warm forging, and hot forging are
differentiated from one another.
Before, there were no techniques or technology for making metal tools and equipment. By
adopting this forging technique, the ancient people produced a wide variety of sharpened weapons,
including swords, axes, knives, and many more.
The term "blacksmith" refers to the person who uses this forging method. To create tools with
the necessary forms, several processes are carried out in the forge. They are upsetting, drawing down,
setting down, bending, forge welding, swaging, fullering, and cutting.

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PRODUCING THE HEXAGONAL BOLT

Required tools; Furnace, Anvil, Big hand hammer, hand hammer, prince hollo bit, hollow bit,
set hammer
We first want a medium grade steel metal rod with a round cross section. The metal rod must
then have one end inserted into the furnace's burning coconut charcoal. The metal rod can be held as it
heats up using a suitable tong, such as a flat mouth forge tong. We can remove the metal end from the
furnace after it reaches an appropriate temperature of 800 Celsius for forging. When the metal rod's end
turns a bright orange color, we know the temperature is high enough.

We should hold it upright and place the heated end on the anvil when it is ready to be
forged. After that, the opposite end of it needs to be promptly hit with a hammer. It should be heated
again once it starts too progressively cool. The upsetting operation is the name given to this technique.
Repeating this technique will result in an increase in the heated end's diameter.

The hot end should next be shaped into a flat form. For that heat once more and hammering as shown
below.

When the cylindrical shape has been transformed into a hexagonal shape, the flattened metal head of
the rod is placed on the anvil and hammered on the flat edge.

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PRODUCING THE CIRCULAR RING

To make this circular ring, we should first acquire an appropriate metal rod workpiece. Now
secure one end of the workpiece to the horn of the anvil. Then, using a hammer, bend that end properly.
The opposite end done by the same action. The result is a ring that is about circular shape. Additionally,
we must maintain an appropriate angle between the metal rod and the horn when we hammer on the
metal rod. Unless using our hands will be an unpleasant activity.
The bent metal rod should now be held upright on the anvil. After that, bang on the top of
it until it takes on a circular shape. Then stack the two ends together and smash them together until it
on a flat shape.

The clay should then be applied to the two flattened ends. The ring is then placed on the furnace and
left there until it reaches the proper temperature for welding. We add some sand to the furnace to raise
the temperature until it reaches the ideal level about 800 degrees Celsius. The sand produced sparks
when it reached the proper temperature. With the aid of a tong, we remove the heated ring and place it
on the anvil if it has reached the proper temperature. Finally, the welding procedure will be finished by
striking the two edges covered by clay with a single hammer shot. After that, cool the ring with water.

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GENERAL SAFETY PRECAUTIONS FOLLOWED IN A BLACKSMITH SHOP

• We should dress fitting dress Because hammers and other instruments are so heavy, wear

safety shoes. Therefore, it will severely harm our bodies.

• When doing this practical, wear safety glasses because it's possible that the hammering will

disseminate some microscopic metal particles into our eyes.

• Any hanging objects, such as wristbands, watches, and hanging threads, pose a safety risk.

Before entering the blacksmith shop, take them off.

• When responding to any emergency situation, always keep the practical aspects in mind.

• Choose clothing that is heat- and fire-resistant to shield you from extreme temperatures,

sparks, and flames.

• We need to clean up the workspace when the task is complete.

DEFECTS OBSERVED DURING THE MANUAL FORGING

• Our bodies can come into direct contact with heated metals.

• The metal rod does not bend into a precise circle when we bang on it.

• Without the required expertise, it is exceedingly challenging to create metal equipment, and
the forging process is quite stressful.

• Because the hexagonal head is positioned in the middle of the metal rod, it cannot be

formed precisely around the rod when the hexagonal bolt is made.

• Surface cracking, which occurs when there is a temperature difference between the surface

and the center or when the surface is overworked at a low temperature.

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PROCESS OF FABRICATING A CHISEL USING BLACKSMITH OPERATIONS

A spring steel specimen is required first. Next a chamfer should then be forged on one end of the bar.

Now use the smith furnace to heat the opposite end of the bar until it reaches about 800 Celsius. Put it

on the anvil horizontally and hold it with a round-mouthed forge tong once it has reached the proper

temperature. The heated end of the rod is then struck by two people standing face to face, each with a

large and a little hammer.

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Now, we can get the final part

The chisel's strength and hardness should now be increased. For that, the chisel is gradually heated to a

temperature of about 800 Celsius and maintained there for a few minutes. The steel's structure changed

from BCC to FCC during this time. As a result, the chisel's hardness is raised. Use water to quickly

cool the chisel after this technique. The FCC structure is unchanged and remains as it was in that case.

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