Workshop Practice (GE102)
Reference manual for the Forging experiment
● Objective(s): (1) To convert a round bar to square bar and make a chisel by
using hot and cold hand forging processes for the given mild steel specimen.
(2) To prepare a J shape component from a round bar of diameter 10 mm
● Introduction: Forging is a process of shaping the metal components in cold or
hot condition by the application of impact or pressure but the primary difference
between various forging methods is the rate which the energy is applied to the
work piece. A blacksmith's work involves heating of a metal to a desired
temperature; enable it to acquire sufficient plasticity, followed by the operations
like hammering, bending, pressing etc., to give it to the required shape. This
process is termed as forging. If the operations are done by means of hand
operated tools then that type of forging is termed as hand forging. It renders the
metal stronger by setting the direction of the grains.
● Materials Required: - Mild steel bar with diameter 10 mm and length 200 mm
(Four quantity)
● Apparatus required: -
(1) Furnace, anvil, tongs, swage block, players, set of hammers, hacksaw, vice,
heat resistance and safety gloves, safety apron, forging pit etc.
(2) Measuring device (Vernier caliper, Steel rule, Try square, Marker pen etc.)
● Procedure: -
1. To fix the mild steel bar with sufficient overhang in the bench vice and cut it
according to the given length by using hacksaw.
2. Place two spaceman samples in the furnace and switch on the furnace with
setting the temperature range between 700 to 900 deg C for the hot forging
process.
3. Collect the remaining two sample and start cold forging process.
4. Make a chisel and J shape hook by using set of hammers, Anvil and swage
block.
5. First two samples after sufficient heating it is take out of the furnace using
tongs and hammering is done using hammers by placing it on the anvil.
6. The process is continued till it gets the required dimensions.
7. Using steel rule and try square accuracy is checked.
Calculations:
Given volume of metal, V =πd^2 /4 x L
Volume of metal after shaping, V=S^2 x L
Volume of the Metal before Shaping = Volume of Metal after Shaping
The dimension of the square bar is ------------ mm
● Precautions:
(1) Must wear proper safety shoes, safety gloves and apron.
(2) Follow proper safety protocol during the operation.
(3) Do not operate furnace without the presence of the technical staff or TA.
(4) Take out the sample after switch of the furnace.
(5) Keep your mouth away from the furnace gate.
(6) Don’t touch the red-hot sample with hands.
(7) Use the proper holding device to hold the sample.
(8) Take care of yourself and your colleagues while striking the hammer.
● Difficulties that may arise
(Write the technical difficulties that you think may arise during the experiment)
● Result: - Thus by performing the required forging operations on the given
material, job with required shape and dimensions is obtained.
● Conclusion:
(What new knowledge(s) one can learn by doing this experiment.
Write short not on application of forging.
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