Group No: G7

Module Name: ME1071

Semester: 2

FAMILIARISATION WITH SMITH

FORGING
By

Index No. Name Marks

200275A JEYARAJ J.S.P.

Group members

Index No. Name

200231L IMADUWA I.N.N.
200243B JAYAKODY J.P.C.L.
200246L JAYALATH J.W.K.N.
200268F JAYAWARDHANA N.V.
200271H JAYAWICKRAMA H.I.K.
200275A JEYARAJ J.S.P.
200278K NILMAN K.A.D.S.
200290N KARUNANAYAKA K.P.N.S.B.
200319N KUMARA M.A.S.J.
200320J KUMARA M.H.R.

Date of practical session

Date of submission

Instructor’s name

Department of Mechanical Engineering

University of Moratuwa
Sri Lanka
 INTRODUCTION

Forging is the process of is the pressing or hammering of metals with or without applying heat to change
their shape. This consists very old techniques which were used for a long time to shape metals to desired
shapes to get useful things done from them. For instance, ancient weapons, farming tools and chariot
wheels and a lot more other components were made using forging techniques.

Though it is an outdated and ancient method still it can be used to get very important uses as casting,
and tempering metals. Smith forging involves few main operations that are performed in a blacksmith
shop. A person who conducts smith forging activities is called as a blacksmith.

The forging operations are as follows,

• Upsetting: Increasing the cross-section area of a bar reducing its length

• Drawing down: Increasing the length of a bar by reducing its cross-sectional area
• Bending: Making angle bends by hammering
• Forge welding: Joining 2 surfaces of a metal by pressure after heating
• Flattening: Making flat surfaces
• Swaging: Using various blocks forming metals into shapes
• Fullering: Reducing cross-sectional are at required points
• Cutting: Cutting a metal rod or plate using chisels and hammers

Various tools are being used in the blacksmith shop to shape these metals. Different types of hammers,
chisels, anvils, tongs (to hold heated objects), swage blocks, set hammers and punches are only a few of
them. The most important component of the blacksmith shop is the hearth or furnace where metals are
heated to do all the forging processes.
 PRODUCING THE HEXAGONAL BOLT HEAD AND CIRCULAR RING

MATERIALS, TOOLS AND MACHINES USED

• Blacksmith Furnace (motor powered blower)

• Double faced hammer (Medium weight)
• Steel rod
• Anvil
• Bench vise
• Rough file
• Smooth file
• Tong

STEPS FOLLOWED FOR THE HEXAGONAL BOLT HEAD

First the demonstrator started up the furnace and put the steel rod’s bolt head side into the fire. After
some time when the end turned red, he took it from the fire and placed the heated side on the anvil face.
Then each team member in our team were asked to hammer the other end using the double face hammer,
while holding it close to the top until enough material is upsetted in the bottom.

After few blows, we could observe that the heated part is straight so time to time we had to hold the rod
at an appropriate angle to anvil face and hammer on the irregular places to straighten them. If this is not
done appropriately the damage could be beyond redemption. This process was continued for several
times after heating the rod again and again.

After hammering for a very long time, enough material was accumulated at the bottom the rod was
heated again and while the demonstrator held the rod horizontally by placing the bottom on the anvil
face, we were asked to hammer it while he rotates it. After a few blows the base was in the shape of a
hexagon. Then after leaving it to cool for some time, we fixed it on a bench vise and filed the head using
a rough file to get the proper hexagonal shape.

STEPS FOLLOWED FOR THE CIRCULAR RING

We were given a thinner steel rod and were asked to make a circular ring using it without applying heat.
We started by keeping the steel rod on the horn of the anvil and continuously hammered to the part
which is just in contact with the horn using a light weight double faced hammer. We took turns and
hammered it until it is curved enough that the impact was too hard to be handled by the hand. Then we
kept the uneven parts on the anvil face and hammered their opposite point. After few blows, we managed
to get the circular shape with one end of the rod is over the other.

Then the demonstrator showed us how we should perform a forge weld. He first applied clay onto the
contact surfaces so that they won’t be oxidised by oxygen at higher temperature. Then the contact
surfaces are heated in the furnace.
When the ends were hot enough the demonstrator brought the ring holding it with a tong and asked one
of us to hammer onto the weld point with the heavy hammer a hard and accurate blow. This should be
done as soon as possible to prevent harm to the steel. After a proper blow we left the ring to cool off.
 SAFETY PRECAUTIONS FOLLOWED IN BLACKSMITH SHOP

No loose clothing or loose hair was allowed in the sheet metal shop since they might get entangled in
heavy objects or can catch fire from the furnace or heated metals. Further protective shoes are
recommended and if they are not available leather shoes are compulsory as heavy tools or heated metal
pieces might fall on to the legs.

Eye protection is recommended as small piece of hot metal or sparks might be thrown away while
hammering or heating.

If a heated object accidentally falls, we should never try to catch it as it can injure us, therefore we let it
fall.

Wearing gloves is advisable since we mostly deal with very hot surfaces.

Hot items should always be held using an appropriate tong.

DEFECTS IN MANUAL FORGING

There are several defects that can be observed during manual forging. They are unfilled section, cold
shut, flakes, surface cracking, and residual stresses.

1. Unfilled section: This is when there is an unfilled portion in the component after forging. This
happens due to poor forging technique, poor heating, or poor die design. Doing the above
processes with care could help prevent this defect.
2. Cold shut: This happens when there are crack at the corners of the object. This could be
reduced by increasing the fillet radius during design.
3. Flakes: Internal cracks have been formed inside the object. This happens due to improper
cooling of forged objects. This vastly reduces the strength of the object.
4. Surface cracking: Cracks are formed on the objects surface. The main reason for this is that the
forging operation being carried out at a lower temperature than the optimal temperature.
5. Residual stresses: These also occur due to improper cooling of the forged parts. This creates
unexpected stresses in the object. Slow cooling of the forged part is a remedy for this defect.
 RECTANGULAR DUCT WITH END CONNECTIONS

MATERIALS, TOOLS AND MACHINES USED

• Blacksmith Furnace (motor powered blower)

• Double faced hammer (Medium weight)
• Hexagonal medium carbon steel rod
• Anvil
• Bench vise
• Rough file
• Smooth file
• Tong

STEPS FOLLOWED

Firstly, the rod’s back is heated is the furnace and hammered in the hex edges to get the desired
rounded edges. Then, the tip side is heated in the furnace until red hot. Then it is taken out using a pair
of tongs and kept on the anvil. Then the two sides that is planned to be squashed are hammered
alternatively. The hammering is done to alternate sides to prevent over compression of side. This is a
type of drawing down process where the cross-sectional area is reduced to transfer the material to the
tip.

Then the hammering is continued until the desired tip shape is obtained. Then the workpiece is left to
cool slowly for a short while. After cooling the workpiece is mounted on a bench vise and unnecessary
parts are filed down using the rough file while smoothening and obtaining the required shape. Then
using the smooth file. This tip is further sharpened and smoothened.

Once the required sharp tip is obtained the tip is reinserted into the furnace and is heated to a very high
temperature till the chisel colour became white. Then the chisel is taken out and water is poured until
the tip’s colour turns to blue. Once the blue colour is obtained, we insert chisel into the water and
suddenly cool it. This is done to harden the tip by changing its phase.
REFERENCES

• Steelforging.org. 2022. Common Defects of Steel Forgings | Steel Forging. [online] Available
at: <https://www.steelforging.org/common-defects-of-steel-forgings/> [Accessed 22
September 2022].

• “Different types of forging defects, Cause and their remedies - studentlesson,” Student Lesson,
2022. [Online]. Available: https://studentlesson.com/types-of-forging-
defects/#:~:text=Types%20of%20forging%20defects%20include,and%20residual%20stresses
%20in%20forging. [Accessed: 2022].
• malam169, “How to forge a chisel for Blacksmith,” Blacksmith Code, 28-Jun-2021. [Online].
Available: https://blacksmithcode.com/how-to-make-a-chisel/. [Accessed: 23-Sep-2022].