Unit 4: Forging

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4.1 Introduction to forging
4.1.1 Introduce to hand forging, its applications, advantages and
limitations
Hand forging is a traditional metalworking process where a blacksmith
manually shapes metal using a hammer and anvil. The metal is heated
in a forge until it becomes malleable, then hammered into the desired
shape.
This process is one of the oldest metal-forming techniques and is
widely used in small-scale production, artistic blacksmithing, and repair
work.

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4.1 Introduction to forging
Applications of Hand Forging
• Custom Tool Making – Used for crafting specialized tools and implements.
• Artistic Metalwork – Produces decorative items like gates, railings, and
sculptures.
• Repair and Maintenance – Helps in fixing broken or worn-out metal parts.
• Small-Scale Manufacturing – Creates unique, non-standard components.
• Prototype Development – Useful for making initial models before mass
production.

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4.1 Introduction to forging
Advantages of Hand Forging
• High Strength – Improves grain structure, making the metal stronger.
• Customization – Allows for unique and intricate designs.
• Flexibility – Can be used for various metals and shapes.
• Minimal Equipment Required – Needs only basic tools like a hammer,
anvil, and forge.

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4.1 Introduction to forging
Limitations of Hand Forging
• Labor Intensive – Requires significant physical effort.
• Time-Consuming – Slower compared to modern automated forging
methods.
• Size Limitations – Not suitable for large-scale or heavy metal
components.
• Inconsistency – Quality depends on the skill of the blacksmith.

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4.1 Introduction to forging
Common Forging Materials:
• Ferrous Metals:
• Carbon Steel – Most commonly used due to its strength and versatility.
• Alloy Steel – Enhanced with elements like chromium and vanadium for better performance.
• Stainless Steel – Corrosion-resistant and used in medical and food industries.
• Cast Iron – Limited forging use due to brittleness but can be reshaped in some cases.
• Non-Ferrous Metals:
• Aluminum – Lightweight, corrosion-resistant, and used in aerospace and automotive
industries.
• Copper and Brass – Good electrical conductivity, used for decorative and electrical
components.
• Titanium – Strong, lightweight, and resistant to high temperatures, commonly used in
aerospace and medical fields.
• Nickel Alloys – High strength and corrosion resistance, ideal for high-performance
applications.

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4.1 Introduction to forging
• 4.1.3 Safety in Forging Practice
• Forging involves high temperatures, heavy machinery, and physical labor, making
safety a top priority. Proper precautions help prevent injuries and ensure efficient
operations.
• Safety Precautions in Forging:
• Personal Protective Equipment (PPE):
• Wear heat-resistant gloves, safety goggles, and face shields.
• Use flame-resistant clothing and steel-toe boots.
• Ear protection is necessary to reduce noise exposure.
• Workplace Safety:
• Keep the work area clean and free of obstructions.
• Ensure proper ventilation to remove fumes and excess heat.
• Use fire-resistant materials around the forge to prevent accidents.

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4.1 Introduction to forging
• Handling Hot Metals:
• Always use tongs or specialized tools to handle heated metal.
• Never touch hot metal directly, even if it appears cool.
• Quench and cool metals properly to prevent burns and explosions.
• Equipment Maintenance:
• Regularly inspect hammers, anvils, and presses for wear and damage.
• Ensure proper functioning of the forge and gas supply to prevent leaks.
• Keep hand tools clean and free from oil or grease for a secure grip.
• Fire and Emergency Preparedness:
• Have fire extinguishers and sand buckets nearby.
• Train workers in fire safety and first aid procedures.
• Know emergency exit routes and have a plan for accidents.

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4.2 Hand forging operations
4.2.1 Tools: nomenclature, application
1. Basic Tools:
• Forge – Heats the metal to make it malleable. Furnace or hearth.
These forging tools are used by blacksmiths for heating metal pieces
• Anvil – Provides a surface for shaping metal.
• Hammer – Used to strike and shape metal (e.g., cross-peen hammer,
ball-peen hammer).
• Tongs – Hold and manipulate hot metal securely.
• Chisels – Cut metal pieces (hot chisel for heated metal, cold chisel for
unheated metal).
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4.2 Hand forging operations
2. Specialized Tools for Specific Operations:
a) Fullers – Create grooves, indentations and
spread metal.
b) Swages – Shape round or hexagonal sections Fuller
forging tool type that gives various shapes to the workpiece.
It is also made of high-carbon steel.

c) Drifts – Enlarge holes in metal.

d) Punches – Create holes in metal sheets or bars.
e) Set Hammers – Flatten or refine metal edges.
f) Flatters – Smooth the surface of forged metal. Sawages

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4.2 Hand forging operations
4.2.2 Hand Forging Operations
1. Bending
• Involves curving or angling metal using a hammer over the anvil or a
bending fork.
• Used in making hooks, rings, and decorative metalwork.
2. Cutting Down
• Reduces metal thickness by striking with a hammer and chisel.
• Helps in making joints and reducing excess material.
3. Setting Down
• Creates sharp corners or stepped sections in the metal.
• Done using a set hammer or edge of an anvil.
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4.2 Hand forging operations
4. Swaging
• Shapes metal into round, square, or hexagonal sections using swage blocks or tools.
• Common in making shafts and rounded edges.
5. Squeezing
• Compresses metal between tools or the anvil to shape it.
• Used in reducing metal thickness or shaping.
6. Drawing
• Lengthens the metal while reducing its cross-section by hammering, pulling and stretching in the
cross-sectional area.
• Used in making rods, tapering edges, and wire drawing.
7. Twisting
• Rotating a heated metal piece to create decorative patterns.
• Common in making artistic railings and tools.

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8. Upsetting
• Thickens the metal by shortening its length through repeated hammering.
• Used in making bolt heads and rivet heads.
9. Punching
• Creates holes in the metal using a punch and hammer.
• Used for bolt holes and decorative designs.
10. Fullering and Drifting
• Fullering: Uses fullers to spread metal and create grooves.
• Drifting: Enlarges holes made by punching.
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Fullering

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4.3 Power forging
4.3.1 Power hammer: types, working, application and care (drop, press
machine)
A. Drop Hammer
• Also known as a Gravity Drop Hammer or Mechanical Forging Hammer.
• Uses gravity or a mechanical system to drop a heavy ram onto the
workpiece.
• Common types:
• Gravity Drop Hammer: Uses free-falling weight.
• Steam or Air Drop Hammer: Uses compressed air or steam for additional force.
• Board Drop Hammer: Uses a friction-driven board to lift and drop the hammer.

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Drop Hammer Working
i. The hammer is lifted using a mechanical, pneumatic, or hydraulic system.
ii. It is released to fall freely or with controlled force.
iii. The impact deforms the workpiece placed on the anvil or die.
iv. The process is repeated until the desired shape is achieved.

Drop Hammer Applications

• Forging automotive parts (crankshafts, connecting rods).
• Coining and stamping operations.
• Manufacturing hand tools (spanners, pliers).
• Metal shaping and compression forming.

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4.3 Power forging
B. Press Machine (Forging Press)
• Applies gradual and continuous pressure instead of impact force.
• Types include:
• Hydraulic Press: Uses hydraulic fluid for force application.
• Mechanical Press: Uses a flywheel and crank mechanism.
• Screw Press: Uses a rotating screw for pressure application.

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4.3 Power forging
Press Machine Working
i. A continuous force is applied to the workpiece using hydraulic, screw, or
mechanical pressure.
ii. The metal is deformed gradually instead of sudden impact.
iii. Used for deep drawing, bending, and shaping operations.
Press Machine Applications
i. Sheet metal forming (bending, drawing, punching).
ii. Manufacturing aircraft and automobile body parts.
iii. Powder metallurgy compaction.
iv. Hot and cold forging applications.

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4.3 Power forging
Care and Maintenance
• Lubricate moving parts regularly to reduce wear.
• Check alignment of hammer or press die to prevent faulty production.
• Inspect hydraulic and pneumatic systems for leaks and pressure
inconsistencies.
• Monitor vibration and noise levels to detect early signs of machine
failure.
• Keep the work area clean and free of metal debris for safety.

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4.3.2 Defects on forging process, cause and their possible remedies

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Defect Cause Remedy

- Incorrect die design - Modify die design

Laps and Folds (surface irregularities,
- Excessive material flow - Ensure correct material flow
overlapping material layers)
- Poor metal distribution - Reduce excessive deformation

- Maintain proper forging

- Incomplete metal flow
Cold Shut (small cracks or temperature
- Low forging temperature
discontinuities at the surface) - Improve metal flow
- Poor die design
- Modify die design for better filling

- Clean metal surface before forging

Scale Pits (surface indentations due - Presence of oxides on metal surface
- Use controlled atmosphere
to oxidation) - Improper heating in furnace
furnaces

- Insufficient material - Use appropriate billet size

Underfilling (incomplete metal filling
- Low forging pressure - Increase forging pressure
in die cavity)
- InadequateErpreform
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shape - Ensure proper die design 29
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 - Align and secure dies properly
Die Shift (misalignment of upper - Improper die setting
- Regular inspection of machine
and lower die halves) - Machine misalignment
setup
- Excessive stress concentration - Optimize forging temperature
Cracks (internal or surface cracks) - Overheating or improper cooling - Control cooling rate
- Poor material quality - Use high-quality raw materials

- High carbon steel with improper

Flakes (internal fractures due to - Use controlled cooling techniques
heat treatment
rapid cooling) - Modify heat treatment process
- Rapid cooling of hot metal

- Excessive heating temperature - Optimize heating process

Surface Cracks and Burns - Overworking of metal - Reduce excessive deformation
- Poor lubrication - Apply proper lubricants

- Improper die alignment - Ensure correct die alignment

Mismatch (Misalignment of die
- Uneven die wear - Regular maintenance of dies
halves)
- Poor machine setup - Proper fixture settings
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4.4 Heat treatment of forged materials
4.4.1 Introduction and purposes of heat treatment
Introduction
• Heat treatment is a controlled process of heating and cooling metal to alter its
physical and mechanical properties without changing its shape. It is widely used
in forged materials to improve their hardness, toughness, strength, and
machinability.

Purposes of Heat Treatment

• Enhance Mechanical Properties: Increases strength, hardness, toughness, and wear
resistance.
• Refine Grain Structure: Improves ductility and reduces internal stresses.
• Improve Machinability: Softens the metal for easier cutting and shaping.
• Remove Internal Stresses: Prevents warping and cracking in further processing.
• Increase Resistance to Wear and Corrosion: Extends the lifespan of components.

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4.4 Heat treatment of forged materials
4.4.2 Types and Uses of Heat Treatment
1. Annealing
Process:
• The metal is heated to a specific temperature (above the critical point).
• It is then slowly cooled in a furnace.
Purpose:
• Softens the metal.
• Improves machinability.
• Refines grain structure.
• Relieves internal stresses.
Applications:
• Used for steel, copper, aluminum, and brass.
• Common in automotive parts, structural components, and sheet metal.

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4.4 Heat treatment of forged materials
2. Hardening
Process:
• The metal is heated above its critical temperature.
• It is rapidly cooled (quenched) in water, oil, or air.
Purpose:
• Increases hardness and strength.
• Enhances wear resistance.
Applications:
• Used for tools, gears, knives, and machine parts.
• Common in manufacturing of cutting tools, bearings, and dies.

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4.4 Heat treatment of forged materials
3. Tempering
Process:
• The hardened metal is reheated to a lower temperature (below the critical point).
• It is then cooled at a controlled rate.
Purpose:
• Reduces brittleness while maintaining hardness.
• Increases toughness and ductility.
• Relieves internal stresses.
Applications:
• Used in springs, shafts, and automotive components.
• Common in manufacturing of tempered steel tools, gun barrels, and crankshafts.

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Extras ( Types of forging operation)

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Extras(open die forging)

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Extras(impression die forging)

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