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    Black Smithy Shop

    Uploaded by

    Amarjeet Singh (Assistant Professor- Mechanical Engineer)
    The document provides an introduction to blacksmithing and forging processes, describing common hand tools such as tongs, fullers, and hammers used to shape hot metal through techniques like drawing, upsetting, and bending. It also outlines an experiment to make an S-hook from a round rod using hand forging operations including heating, bending, and flattening the metal into the desired shape.

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    © All Rights Reserved
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    Black Smithy Shop

    Uploaded by

    Amarjeet Singh (Assistant Professor- Mechanical Engineer)
    92 views3 pages
    The document provides an introduction to blacksmithing and forging processes, describing common hand tools such as tongs, fullers, and hammers used to shape hot metal through techniques like drawing, upsetting, and bending. It also outlines an experiment to make an S-hook from a round rod using hand forging operations including heating, bending, and flattening the metal into the desired shape.

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    The document provides an introduction to blacksmithing and forging processes, describing common hand tools such as tongs, fullers, and hammers used to shape hot metal through techniques like drawing, upsetting, and bending. It also outlines an experiment to make an S-hook from a round rod using hand forging operations including heating, bending, and flattening the metal into the desired shape.

    Copyright:

    © All Rights Reserved
    Download as DOCX, PDF, TXT or read online from Scribd
    Download as docx, pdf, or txt
    92 views3 pages

    Black Smithy Shop

    Uploaded by

    Amarjeet Singh (Assistant Professor- Mechanical Engineer)
    The document provides an introduction to blacksmithing and forging processes, describing common hand tools such as tongs, fullers, and hammers used to shape hot metal through techniques like drawing, upsetting, and bending. It also outlines an experiment to make an S-hook from a round rod using hand forging operations including heating, bending, and flattening the metal into the desired shape.

    Copyright:

    © All Rights Reserved
    Download as DOCX, PDF, TXT or read online from Scribd
    Download as docx, pdf, or txt
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    Program: B Tech Semester: 1st

    Course: Workshop Practice Course 23BTAL11C08


    Code:

    Black Smithy Shop


    INTRODUCTION
    Black smithy or Forging is an oldest shaping process used for the producing small articles for
    which accuracy in size is not so important. The parts are shaped by heating them in an open fire
    or hearth by the blacksmith and shaping them through applying compressive forces using
    hammer. Thus forging is defined as the plastic deformation of metals at elevated temperatures
    into a predetermined size or shape using compressive forces exerted through some means of
    hand hammers, small power hammers, die, press or upsetting machine. It consists essentially of
    changing or altering the shape and section of metal by hammering at a temperature of about
    980°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.

    COMMON HAND FORGING TOOLS


    Tongs
    The tongs are generally used for holding work while doing a forging operation.
    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 to be reduced or finished to round, square or
    hexagonal form. It is made with half grooves of dimensions to suit the work being reduced.
    Fuller
    Fuller is used in forging shop for necking down a forgeable job.
    Punch
    Punch is used in forging shop for making holes in metal part when it is at forging heat.
    Rivet header
    Rivet header is used in forging shop for producing rivets heads on parts.
    Chisels
    Chisels are used for cutting metals and for nicking prior to breaking. They may be hot or cold
    depending on whether the metal to be cut is hot or cold.
    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) cross peen hammer.
    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
    It is used for finishing corners in shouldered work where the flatter would be inconvenient. It is
    also used for drawing out the gorging job.
    Anvil
    An anvil is a most commonly tool used in forging shop which is shown in. It acts as a support for
    blacksmith’s work during hammering.
    Swage block
    It is mainly used for heading, bending, squaring, sizing, and forming operations on forging jobs. It is 0.25
    mt. or even more wide. It may be used either flat or edgewise in its stand.

    FORGING OPERATIONS:

    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.

    3. Fullering: Fullers are used for necking down a piece of work, the reduction often serving as
    the starting point for drawing.

    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.

    5. Swaging:
    Swages like fullers are also made of high carbon steel and are made in two parts called the top
    and swages. These are used to reduce and finish to round, square, or hexagonal forms.

    6. Bending:
    Bending of bars, flats, etc., is done to produce different types of bent shapes such as angles,
    ovals, circles etc.

    7. Twisting:
    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 pieces may be clamped in a leg vice and
    twisted with a pair of tongs or a monkey wrench

    8. Cutting (Hot and Cold Chisels):


    Chisels are used to cut metals, either in hot or cold state. The cold chisel is similar to fitter’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.
    Experiment

    Aim: To make an S-hook from a given round rod, by following hand forging operation.

    Tools required: Smith’s forge, Anvil, 500gm and I kg ball-peen hammers, Flatters, Swage
    block, Half round tongs, Pickup tongs, Cold chisel.

    Sequence of operations:
    1. One end of the bar is heated to red hot condition in the smith’s forge for the required
    length.
    2. Using the pick-up tongs; the rod is taken from the forge, and holding it with the half
    round tongs, the heated end is forged into a tapered pointed end.
    3. The length of the rod requires for S-hook is estimated and the excess portion is cut-off,
    using a cold chisel.
    4. One half of the rod towards the pointed end is heated in the forge to red hot condition and
    then bent into circular shape as shown.
    5. The other end of the rod is then heated and forged into a tapered pointed end.
    6. The straight portion of the rod is finally heated and bent into circular shape as required.
    7. Using the flatter, the S-hook made as above, is kept on the anvil and flattened so that, the
    shape of the hook is proper.

    NOTE: In-between the above stage, the bar is heated in the smith’s forge, to facilitate forging
    operations.

    Precautions:
    1. Hold the job carefully while heating and hammering
    2. Job must be held parallel to the face of the anvil.
    3. Wear steel-toed shoes.
    4. Wear face shield when hammering the hot metal
    5. Use correct size and type of tongs to fit the work.

    Result:
    The S-hook is thus made from the given round rod.

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