What is metal forging

How to forge metal at home

Translated by SaorY for mozgochiny.ru

Greetings to all brain crafters ! After almost a year of “communication” with a hammer and an anvil, I finally acquired the necessary experience and tools to create forged crafts , such as the small “Damascus” knife from this brain article .

And I started, by the way, with a small sledgehammer as an anvil, which I hit with a small hammer.

Now we will talk about creating a small, forged, not carved, knife with your own hands using a homemade forge, anvil, hammer and determination. I don’t pretend to be a professional, and this is certainly not the only way to obtain welded Damascus; this is the story of how I managed to make it.

Damascus steel today is called welded Damascus, obtained from welded metal plates of various brainsteels , subsequently forged and twisted. It's like molding different colors of plasticine together and twisting it to create a wavy pattern. After forging, such a workpiece is subjected to etching, in which the dissimilar metals of the workpiece are eroded unevenly, thereby creating a beautiful contrast.

The original Damascus steel is obtained in a different, very specific way (although it looks similar to modern Damascus), and few people know how to create it; this fact has given Damascus a reputation as a metal supposedly endowed with magical powers.

And the reason for this “power”, similar to samurai swords, is a process that makes it possible to obtain a more homogeneous, and therefore with the desired qualities, steel, which cannot be achieved in other ways, and makes it possible to include low-quality and high/low carbon steel in the workpiece. Which results in a much better quality blade.

!!! ATTENTION!! A knife can be dangerous, please do not give it to people with mental disorders!!!

Step 1: Materials and Tools

- steel plates of two or more grades (preferably high carbon content) that will contrast with each other, I took high carbon 1095 steel and 15n20 steel, with a small nickel content, which will add brightness and contrast after etching - flux (borax, which can be purchase at a hardware store) - a piece of reinforcement, a long rod (will be welded to the workpiece as a handle) - wood of your choice for the knife handle - epoxy resin (hardening in 5 minutes is the best) - brass rivets - composition for processing the wood of the handle, I I used linseed oil - metal hardening oil (vegetable)

- ferric chloride

- an anvil (preferably a real steel anvil, although if you don’t have one, some other durable objects will do: a piece of rail, a sledgehammer, a large metal blank, an old bollard mooring post, or just a large strong, hard and flat surface. Remember how it all started with strikes with a stone on a large stone) - a hammer (I used a weight of 1.

3 kg, with a cross striker) - pliers - welding (optional, but desirable for welding the plates to each other and welding the handle, if you do not have welding, you can tightly wrap the plates with wire) - forge (capable of heating the workpiece to the temperatures required for forging , which is very important for high-quality fusion of the plates with each other, more on this later) - a belt sander or file with a lot of patience - an oven or another hardening method - a drill or drilling machine

- vice (very useful thing)

Step 2: Assembling the workpiece

Steel plates are cut to the required brain dimensions , mine, for example, are 7.6x1.2cm; Moreover, the larger the workpiece, the more difficult it is to shape it with a hammer. Before welding them in a stack, the plates are cleaned from all sides of rust and scale. Next, the plates are stacked, alternating steel grades, so my workpiece consisted of 7 plates, three of which were grade 15n20, and four of which were grade 1095.

The plates, aligned relative to each other, are welded together (don't pay too much attention to my seam), and then a handle is welded to the stack to make it easier to handle the workpiece during forging. There is nothing wrong, especially after the stack of plates have been welded, in using only pliers. I forged my own anyway.

Step 3: First Forging of the Stack

A little about my forge: I made it with my own hands from an empty (I bought a new one on purpose as a precaution) gas cylinder, lined inside with a 5cm layer of kaolin wool and fireproof cement. It is heated by a Ron-Reil type burner, about which there are many good brainstorming articles . The forge itself is not particularly large and can be heated to the required temperature without any problems.

So, the workpiece from the plates is heated to a cherry-red color; the heat for this does not need to be very strong. The heated homemade is sprinkled with borax, which immediately begins to melt and must be allowed to seep between the plates. This will remove scale and prevent oxidation by preventing oxygen from contacting the metal. This action will ensure the purity of the workpiece metal.

Then the workpiece is heated again in the forge and the procedure is repeated a couple more times, not forgetting to clean the scale if necessary. And after this, the workpiece is heated to forging temperature, I can’t say exactly how much, but I believe it’s somewhere in the region of 1260-1315 degrees Celsius. At this temperature, the workpiece will have a very bright yellow-orange color, similar to moderate daylight.

To avoid wasting time, make sure that the anvil and hammer are at hand and there is enough free working space.

Then the workpiece is quickly placed on the anvil and with light, soft blows, evenly over the entire area, the forging of the plates begins. Next, the workpiece is again placed in the forge and heated to forging temperature, and then forged with blows of medium force.

And after this, the workpiece is stretched so that it can be bent.

Step 4: Folding the workpiece

It's time to increase the number of brain layers in the workpiece. To do this, the workpiece is forged to a length twice the original length, but it is important to stretch it evenly and not just stretch it.

In the middle of the stretched workpiece, a transverse recess of 3/4 or 4/5 thickness is made using a notch, chisel or other suitable method, along which the workpiece is then folded in half on the edge of the anvil, turned over and forged along the entire length, making sure that the halves do not moved relative to each other along the lateral edges.

Then the heating/forging process from the previous step is repeated: flux, heat, cool, heat, forge, forge. The procedure for increasing the number of layers is repeated until the required number of these layers, so I folded it 4 times and got 112 layers. (If you want more layers, please, the pattern will then be smaller. The formula for calculating the layers is as follows: initial number * 2 to the power of the number of folds, that is, 7 * 24 = 112).

homemade workpiece, heated to forging temperature, is placed in the groove of the anvil, twisted thoroughly, and then it is again given a rectangular shape. But before twisting, the workpiece is punched in the corners so that its shape becomes more rounded, because when twisting and reverse forging into a rectangular workpiece, inclusions and impurities can form from the resulting folds if the temperature of the workpiece is lower than the forging temperature.

After this, the brain blank is forged again (I repeated it several times), and cooled, and to make sure that the forging is uniform, I cleaned one of the ends of the blank. During the forging itself, especially at the first stage, it is important to keep the temperature of the workpiece high and be careful, otherwise you can tear the layers away from each other (this is also called delamination, which is not at all good).

Step 5: Model and Rough Profiling

Now you need to imagine the profile of the future knife and roughly forge it from the blank. The more accurately you can forge the profile and bevel, the less you will have to bother with grinding (on a machine or with a file). There are many brain articles from more experienced blacksmiths, so I will not go into detail. The bottom line is that the workpiece behaves approximately like plasticine; when it is heated, it is necessary to punch it in the desired direction.

Step 6: Sanding the Profile

The final shaping of the profile is carried out with a grinder and a file. Stock up on tea, because most likely this will take a lot of time, unless of course you have a brain grinding machine .

Step 8: Finished profile

After the profile of the craft is formed, it still needs to be finalized with a file with a finer grain, I used 400s. The edge of the blade is sharpened almost, but not completely; it is necessary to leave it slightly unsharpened so that during hardening the edge material does not deform. After this, holes for rivets are drilled in the knife handle and wooden dies for this handle are prepared.

Step 9: Exciting Moment

Hardening.
It will either “make” your blade or destroy it. It is important to concentrate and be careful, otherwise you can deform and destroy the blade. The method I used is not the most thorough brain-hardening , but it was the only one available to me with the tools I had, and the oil was the best I could get.

  DIY roller metal shears drawings

Before hardening, the blade must be normalized. This will relieve stresses built up during forging and twisting and reduce the likelihood of warping during hardening. This normalization is done by heating the blade above its critical temperature (when it is no longer magnetized, so it is useful to have a magnet on hand) and cooling it in air.

The process is repeated three to five times, so I did this 5 times. In addition, this action will help you practice removing the blade from the forge, because no hesitations are allowed during hardening. This action is shown in the photo with my dangling knife.

What’s also cool about this part is that during cooling, oxidation occurs, which begins to reveal the pattern of the steel.

Hardening: the blade is again heated above the critical temperature, and then quickly removed and placed, first with the tip, in warm vegetable oil (for brands of brainsteel like mine).

To heat the oil itself, you can simply heat something metal and throw it into a container with oil; for example, I used a crutch for sleepers. Stir the oil, this way you will get a more even hardening.

If your steel is high carbon, then do not use water to harden it, it will only ruin the blade because water cools too quickly, which is not suitable for high carbon steel.

The craft should now be treated like glass, because if the blade has been tempered correctly, it is so fragile that it can break if dropped.

After this comes the turn of vacation.

Step 10: Tempering the Metal

Tempering is the process of imparting some hardness to a blade to increase its life and strength. This is achieved by heating the blade at a certain controlled temperature. my brainwork in the oven for an hour at a temperature of 205 degrees Celsius. “Bake” until “ready” appears on the display.

Step 11: Etching

I apologize in advance for the lack of photos of this and the next steps, but the process is quite simple. the instructions supplied with it , and then the blade is kept in it for as long as indicated in the same instructions. In my case, it's 3 parts water to 1 part ferric chloride, and let it sit for 3-5 minutes. The process is truly exciting, and the result looks like Batman's knife.

Step 12: Handle and Sharpening

Again, there are many techniques and instructions on how to make a knife handle and sharpen it, so I’ll do without the brainy details . Let me just say that for my craft I chose cherry dies, which I glued to the handle of the knife using epoxy glue and secured with two brass rivets. I sanded it with 400 grit and coated it with linseed oil.

For sharpening, I do not use any special, labor-intensive method, but mostly use a regular whetstone.

Step 13: Time to pat yourself on the back, the knife is ready

This is my finished knife, about 15cm long. People might think it's quite funny, but I have no idea how this fancy pattern came about.

Thank you for your insight , I hope this is useful to someone!

(Az Source)

Source: http://ooo-asteko.ru/kak-kovat-metall-v-domashnih-usloviyah/

Forging equipment and cold forging of metal at home

04Nov

To produce forged structures for various purposes, it is not necessary to subject the material to special

heat treatment. To give an object the desired shape without the influence of high temperatures, you can use

by cold forging of metal. You can make a variety of parts and blanks with your own hands without resorting to complete

complex of works. In this case, the material is subjected to mechanical influence without heating - it is bent and pressed.

Advantages of cold home metal forging

For some, making beautiful forged crafts is an interesting and exciting hobby. And some start

forge fences, fencing, parts and decorative elements for wickets and gates. They can be placed in your own home

or in a personal plot, in a yard, in a country house or put up for sale. Many masters choose this method.

It has many advantages compared to traditional production.

In artisanal conditions

Skillful owners often use it at home, as it does not require serious investments and financial costs.

There is no need to spend money on a forge and expensive equipment: forge, anvil, chair vice, pliers, hammers.

With minimal costs, the products are in great demand, are not cheap and allow you to make a decent profit.

No setup costs

No need to support a blacksmith. You can organize work in any building: garage, workshop, utility room.

Profitable to sell

Minimizing the costs of setting up a workshop and purchasing expensive forging equipment for cold

forging metal, you reduce the cost of the product. At the same time, the product is in great demand and is not cheap. This

A very profitable business, it quickly pays for itself and brings decent profits.

Line production

Increased labor productivity compared to traditional methods. Large batches can be produced

blanks according to the existing sample.

Lasts a long time

Products are especially valued for their long service life. They do not wear out or deform for many years.

This happens because without exposing the material to extremely high temperatures, its internal

structure. It becomes less plastic than during hot processing and less vulnerable to the influence of external factors.

Artificial aging

Allows you to produce beautiful crafts and “antique” design blanks. Many cottage owners and

mansions will be happy to decorate their home, garden or yard with vintage elements. Popular:

• legs of tables and chairs;
• fireplace sets;
• railings for stairs;
• candlesticks;
• bed frames;
• hangers;
• frames for pictures and mirrors;
• flower stands;
• weapon;
• armor;
• lamps.

Watch a video about how a master creates metal blanks with his own hands using a cold forging machine:

Use in everyday life

Technology is required to:

• change the pipe configuration;
• make fences and fences;
• make strong and reliable grilles for windows;
• forge original interior items.

The last option is the most popular among manufacturers and customers.

Always appropriate

The items have classic shapes, look solid and expensive, and never go out of style. They are able to give a strict and respectable

look to any room.

Author's design

The designs are unusual, intricate, with beautiful curls. They allow you to create a unique,

refined and sophisticated style.

Long lasting

They do not break and collapse under the influence of time, moisture, ice, or temperature changes. Therefore they are often used

for decoration of courtyards, personal plots, gardens and parks.

How to care for forged items

Another advantage is easy maintenance. The structures do not require delicate handling or special cleaning agents.

If you place them at home, simply wipe with a damp sponge and apply a layer of protective paint. Update it

need once every 2-3 years.

If these are exterior items (fences, gratings, gates, fences, poles, lanterns, street lamps), during the manufacture

A durable protective coating must be applied on top. From time to time check the condition of moving elements (locks,

hinges, latches) and lubricate them.

It is not recommended to use abrasives or hard sponges. They can scratch the top layer and the product will lose

your attractive appearance. You should also avoid prolonged contact of the surface with moisture to prevent rust from forming.

Artistic metal forging at home - necessary equipment

To set up your own blacksmith shop and set up production, there is no need for large financial investments.

You don't need to buy a lot of equipment. Many things are likely to be found in any owner’s home. These are hammers, tongs,

ticks. You will also need a vice and cutting equipment. But in addition to the tools, you will need to purchase some special

devices or make it yourself according to the drawing.

Welding machine

For everyday use, it is enough to buy a simple model. It is easy to use and inexpensive - within

five thousand. Suitable not only for experienced but also for beginners.

Bulgarian

You will need this device for cutting parts, as well as for grinding knots and seams after welding.

A good powerful model costs about 2500-3000 rubles.

Cleaning sander

It is convenient to align seams, especially for carved openwork grilles, gates or fences. You will spend about 2500 rubles on it.

Hammer

Needed to drill through material. An electric drill can be a replacement. Costs about 4500 rub.

Types of do-it-yourself cold forging machines

For home use, craftsmen choose manually operated devices. They are convenient, have high performance and

do not require large electricity costs.

Gnutik

This tabletop tool is similar to a pipe bender. It is a steel plate on which two

support shaft and moving stop. A manual bender is one of the most necessary devices. It is used to obtain elements

welded structures, production of wavy or zigzag parts. Zigzag angle, pitch and wave height are adjustable with

using a roller or wedge, and then the workpiece is bent according to the programmed parameters.

Twister

This longitudinal twisting tool is included in the basic kit of the beginning blacksmith. He twists the twig

around the longitudinal axis. The end of the part is placed in a stationary vice and securely fixed. On the other edge of the device is located

knob or electric drive. With their help, the part is tightened with a screw according to the principle of a chuck for an electric drill. Experienced craftsmen,

Those with a certain skill can insert a bunch of metal rods into a vice and make a three-dimensional basket.

Snail

One of the most common and frequently used devices. Consists of three sections. They can be changed at will

to obtain parts of different radii. The bending tool itself is located in a horizontal plane.

Before starting work, make a preliminary drawing. It’s so convenient to calculate dimensions and

dimensions. Already according to the received template, the step is measured.

With its help, the “Snail” machine produces the following elements:

• curl;
• comma;
• currency (monogram);
• kalach

Flashlight

It is not used often, since the scope of this device is narrow. Allows you to do only certain things

designs - “flashlight” or “basket”. They are voluminous and have an unusual, bizarre shape.

Wave

Designed to produce “wave” type elements with changing geometry. The workpiece is placed and fixed

between the rollers. Turning the handles all the way, unfold the part and repeat the action.

Buy equipment from us

All necessary devices for your workshop are available for order. Machines for artistic cold forging of metal Rosta LLC

will allow you to create products of any complexity; there are options for beginning craftsmen. In addition, the cost of our

devices are lower than those of foreign analogues.

Call 8 (908) 135-59-82; (473) 239-65-79; 8 (800) 707-53-38 and managers will answer your questions.

Source: http://rocta.ru/info/kuznechnoe-oborudovanie/

Is it possible to forge metal with your own hands?

You can find forged products in various areas of human life. Window grilles, fences, lanterns, garden furniture and other products made through the forging process look elegant and attract the attention of passers-by. Even with the development of homemade technologies, metal forging did not fade into the background. She continues to gain popularity with renewed vigor.

Types of forging

Metal forging is a process that is used to change the shape and size of workpieces. Processing is carried out using special devices and tools. The workpieces can be heated or remain at room temperature. The process is divided into two methods - hot and cold.

Hot forging method

Hot metal forging involves the process of processing a workpiece after it has been heated. An increase in temperature is required to make the metal more ductile and pliable. The heating temperature depends on the type of material used. After heating it is easier to process the part. This can be done without the use of levers or special equipment.

To heat metal, forges are installed in workshops. Coke coal is used as fuel. It saturates the metal with carbon during heating. However, hot forging is not suitable for all craftsmen. This is due to increased costs for forge fuel and bans on the use of flammable equipment in garages.

Cold forging method

This is a metal processing process that does not require the installation of heating equipment and the expenditure of funds on the purchase of fuel. The blanks are connected by welding, and they are bent and pressed with special devices. Cold forging is a less expensive process that does not require additional workshop space or compliance with strict fire safety requirements.

However, the cold processing method has significant disadvantages.
Without heating, metal hardly changes its shape. To make work easier, the master needs to use manual equipment, the operation of which is based on levers. Mistakes made cannot be corrected. Hot forging or cold forging? My opinion based on the realities of our time.. Antikovka 9 9

Hand forged

Forging with your own hands is a labor-intensive process that requires a person to choose the right metal and tools to be processed. It is easier to use the cold processing method, but it does not provide the same capabilities as the hot method and does not tolerate errors.

Tools

Forging metal at home will require the craftsman not only to have free space and hand tools, but also additional equipment. They will make work easier, improve results and productivity.

For cold forging 

Equipment for the cold processing method is based on the interaction of material and levers:

1. Snail. A tool for creating spirals from metal rods.
2. Twister. A device on which an electric motor can be mounted. Designed for twisting two or more rods together.
3. Press.
4. Flashlight. A device for creating volumetric spiral parts.
5. Wave. As the name suggests, this tool is used to give workpieces a wave shape.

We must not forget about the workbench, welding machine, beam, vice.
Special devices can be made independently or purchased. Cold forging - my machines and devices.

For hot forging

Hot forging of metal is carried out using other tools. Common list:

1. Anvil. Work table for processing workpieces.
2. Horn. Device for heating parts. It can be either homemade or purchased. It is important that it can be used to heat materials up to 1500 degrees.
3. Shperaki. Special anvils for decorative processing.
4. Hand tools. These include a sledgehammer, tongs, and a handbrake.

To perform decorative work, you will need a set of shaped hammers.
Blacksmithing. Blacksmiths. Hot forging. 1h .Shabalin Design

Metal for forging

The metal for forging must be chosen wisely. With a high ductility index, the workpiece will be easy to work with, but the strength of the finished part will be low. Non-ferrous metals lend themselves better to decorative processing. However, they are less durable than black ones. Forging steel and iron is popular. These materials are durable and inexpensive.

When it comes to choosing steel, you need to take into account the percentage of carbon in its composition. The optimal indicator is 0.25%. You also need to choose a material with the least amount of impurities in the composition, since they weaken the structure of the steel.

Forging highlights

Forging with your own hands requires a person to be attentive and careful. When working with metals, you must use protective equipment. The two main forging technologies are cold and hot.

Cold forging method

Cold forging of metal at home involves a simple technological process consisting of several stages:

1. First of all, the master must create a sketch of the future product.
2. Using the special devices described above and hand tools, a person needs to create the patterns that are present in the sketch.
3. The last step is to assemble the parts into one structure. Ready-made patterns are located on the desktop. The master needs to connect them together using a welding machine.

It is enough to learn how to work with welding to successfully create a product using the cold method. After assembling the structure, the welding seams are cleaned and coated with a protective compound. The product can be painted in any color.

Hot forging method

The process of processing metal blanks using the hot method is more complex and labor-intensive. Stages:

1. First of all, a sketch is created.
2. The blanks are heated in a forge. The temperature is selected depending on the type of material used. You can heat the entire surface or heat selected areas that will be processed.
3. Draft. Performed with hammer blows.
4. Using a hammer, the length of the workpiece is increased.
5. Shaped hammers can be used to bend hot workpieces.

If you need to twist two heated parts, a twister is used. When performing hot working, you need to know how temperature affects the visual changes of the metal surface. Blacksmiths who do not use thermometers determine the approximate temperature by eye.

For accurate work, it is advisable to buy an industrial pyrometer.
Forging a knife from a file with your own hands.
Hardening Forging metal is considered a popular method of processing metal blanks. Depending on the technique, it can be done by a person without experience in any available room.

It is advisable for beginners to first learn cold forging.

Source: https://metalloy.ru/obrabotka/kovka/metalla-svoimi-rukami

Forged elements: what are they and their types

Since time immemorial, forged elements have decorated fences and gates of personal plots, country estates and other areas. The production of artistic forging items and forging elements requires certain skills and knowledge, as well as the experience of a blacksmith specialist.

Modern methods allow you to achieve excellent results with little physical effort, using equipment and machines.

What are forged elements?

If you look closely, there are forged elements almost everywhere. Modern design techniques use them in home interiors, with a certain combination of style and taste of the owner.

The simplest forging elements are found on barriers, fences, and gates. In large cities and administrative centers, the usual window and door grilles are also decorated with blacksmith products for decorative purposes.

Forging technologies

Forging is the physical impact on metal, as well as its heating, pressure, and pressure, resulting in the desired product.

It should be understood that the elements of artistic forging are functional parts of the structure, but, in most cases, they are used exclusively as decorative ones.

Automated lines are rarely used in the production of artistic forging; more and more it is manual labor or a semi-automatic process.

There are cold forging methods - bending, twisting, and other actions; hot forging - the direct use of a source of heating the metal to the maximum temperature, followed by physical pressure, impact tools, and other devices.

Handicraft working conditions

Handicraft includes designs and machines made by the blacksmith himself, or in a small workshop (handicraft), not mass produced. Some craftsmen put the collection of machines on stream, which is a source of their constant income.

Types of artistic forging elements

• Twisted rings - rings with ornate lines, serve as the basis for the design of forged decorations, part of mixed projects.
• Decorative pipe - its functions correspond to the characteristics of metal, externally it has a wavy type of surface, it is used as the main tool.
• Twisted pipes of different sizes act as part of a whole structure; as a rule, an artistic idea is constructed from a set of similar objects (stand, decoration of lattice, furniture, fence).

The combination of different forging elements allows you to create original metal decorations.

Source: http://myogorod.ru/blagoustrojstvo-doma/materiali/kovanye-elementy-chto-eto-i-ih-vidy.html

Forging is a metal processing process, types and main operations, what is free forging

Let's start with definitions. Forging is a method of processing metal in order to change it. This is not welding, although the metal is processed primarily using high heat.

Forging is the heating of metal to its forging temperature so that it becomes malleable to form new shapes into workpieces. Each metal has its own characteristics, which include the level of forging temperature.

Aluminum and its alloys can be forged at a temperature of 400°C, copper at 1000°C, and to forge iron it will have to be heated to 1250°C.

Types of processing

The types of forging are as follows:

• Using pneumatic, hydraulic, steam hammers;
• Manual, in which the impact on the metal is direct, with a hammer or sledgehammer.
• Stamping, in which the part, when exposed to it, takes the shape of a stamp.

Forging is the products obtained as a result of forging, including semi-finished products.

Open-loop forging is an alternative to stamping: the part is deformed freely without being placed in a die mold. Additionally, this method is used to improve the quality and structure of the substance, then this is called forging.

After forging, the alloy changes significantly for the better; it becomes stronger and finer-grained due to the destruction of large crystals.

Here you cannot do without powerful cranes and special manipulators of various calibers. This processing method is the most economical of all existing ones. If we talk about mass industrial production, then stamping takes first place in popularity.

Free forging is the domain of single or small-scale forging production.

Forging operations and tools

There are many such operations, these are some types of metal forging, the names speak for themselves:

• draft;
• firmware;
• broach;
• running in;
• rolling out, etc.

This is what a self-respecting blacksmith master should stock up on before work:

• hammer or sledgehammer;
• anvil;
• forge or oven;
• small hand and mechanical hammers;
• pliers for gripping hot pieces of metal
• “holder” – a rod with claws for gripping a blank.

Physics of the process

Let's take a closer look at processing using forging.

Heating the workpiece

The fateful stage: as soon as you heat it up, the forging process will continue. A metal blank is taken that needs to be heated. This is done in forges or heating furnaces - it depends on the size of the workpiece.

First of all, preheat the oven, the criterion for readiness is dark red color. The next stage is placing the workpiece in a hot oven. The workpiece must be hot, otherwise you will get cracks in the inner layers of the alloy.

The preheating temperature will be quite sufficient at 300°C: you can check by the appearance of smoke and the slight ignition of oil on the surface of the part.

When parts or several parts are inside the furnace, the heat is gradually increased to the required level. The relationship here is direct: the higher the temperature, the softer and more ductile the part. But it is absolutely forbidden to overheat the workpieces.

The higher the heating of steel, the higher the risk of the formation of individual crystals with weak bonds, which makes the alloy after forging brittle, with tears and cracks. This undesirable phenomenon is called overheating of steel.

It is important to understand that for efficient and high-quality forging, two things are equally important: the correct temperature level and the gradual heating.

Crimping a metal workpiece

It only seems that metal is a homogeneous and dense substance. In fact, inside you can find various voids and so-called shells. Therefore, the workpiece removed from the oven must be immediately compacted: it is hit with a hammer from the middle to the ends.

The actions performed by the hammer are divided into two stages: preparation and final finishing.

Preparation

The main thing in preparation is to “put in order” the alloy of the workpiece: compact it and give it “rough” the desired shape and size. The preparation stage is also divided into types in terms of shape: solid or hollow cylinders, flat things, rings, stretching, etc.

The method of forging at this stage may also vary; their names are just as funny.

As a result, an octahedron should form. It is pressed again - blows with a hammer with a 1/8 turn, after which a shape with sixteen edges is formed. Then everything goes according to the same scenario to get a cylinder with a significantly reduced diameter.

The workpiece becomes longer, the metal moves along the axis. This processing is called pulling.

During work, you need to monitor the condition of the metal. If, for example, cracks are found on the surface, forging must be stopped and the cracks cut out using a forge chisel.

Examples of free forging - 10 photos.

If the metal part for forging is too large, processing is done in two stages: first, the lower part is crimped and prepared, then the remaining part is heated and processed.

The end of this stage is “profit cutting,” which involves removing the upper “profitable” part of the workpiece due to the void content in it.

To form a part in the form of a ring, a piece of the workpiece needs nothing at all: crimp, stretch, clean from scale, chop off the profit and cut into pieces. We heat these pieces thoroughly a second time and do a wonderful thing - we form cakes from them.

Holes in these cakes are punched on both sides to create real rings. Next, processing is carried out called “layout” in a special anvil of a stand-up type.

One of the most common shapes of workpieces are parts with a rectangular cross-section. Their forging is carried out according to its own rules. Firstly, you need to work on special flat anvils. First, they are crimped, and then they are flattened “flat”.

The next stage is to rotate the workpiece along the axis by 90°C and flatten it “on edge”. Under impacts and flattening, the part becomes longer along the axis.

To ensure that it does not turn into a thin ribbon, it is simultaneously “rolled out” to expand the dimensions, and all resulting irregularities are smoothed out with a hammer. This is how armor plates are forged.

There are a huge number of options for blanks based on the shape and nature of the metal. There are also many ways of forging. You need to be able to choose the most optimal one and plan the sequence of open forging operations.

The quality of forging and the consumption of resources in the form of energy for repeated heating and other consumables will depend on the correctness of this choice.

Final finishing

As a result of the processing stage, the workpiece has a completely non-marketable appearance - it is more like a metal draft. It is uneven, with a rough surface and does not always coincide with the required dimensions. Bringing it into complete order is the content of this stage of forging.

The part is cleaned with a chisel to remove cracks and hairs. Then they go over the entire surface with a hammer. The next step is to check the dimensions and irregularities with special rulers and correct any discrepancies.

There are special smoothers and stamps for the final “polishing” of metal surfaces. All these smoothing actions are carried out only when the parts, which are at the stage of brown-red heat, have cooled. That's why they are called cold forging or cold forging.

The next state of the workpiece metal is a decrease in its ductility and general hardening. This is an extremely important moment, since at this stage there is a risk of cracks due to the low mobility of the metal itself and the disruption of bonds between particles after forging.

The larger the size of the produced metal workpiece, the more difficult the cooling process is with various manifestations of internal tensions, which can cause unwanted deformation of the metal. To avoid such troubles, the part is buried in hot garbage after forging.

The main thing is to catch it while it’s still red. This method is suitable provided that the part is not God knows how large and complex. If the workpiece has a complex design, additional annealing is performed - heating to a temperature level of approximately 700°C, followed by slow cooling in a furnace with sealed cracks.

Recently, hydraulic presses have appeared and are increasingly used, which serve as a classic forging hammer. They are called presses or press hammers.

In short, open-loop forging is the art of compromise; you need to know the basic forging operations in order to determine the method, shape and type of tools used. This requires experience and skill. It's worth it.

Source: https://tutsvarka.ru/kovka/svobodnaya

Do-it-yourself cold forging: simple examples of products and tips for work

Recently, the demand for exclusive products has increased significantly. One has only to look at a forged gate or grille, and one immediately gets the impression of luxury and wealth. Many people are interested in how to make products using the cold forging method with their own hands, and it turns out that it is not at all difficult.

Do-it-yourself artistic forging has firmly taken a leading position in the modern market. These products can be found not only on fences and gates, but also on beds in ordinary apartments. There are several types of products where forging is used most often:

1. Gates.
2. Fences.
3. Lattices.
4. Stairs.
5. Gazebos, barbecues.
6. Furniture and its accessories.

In practice, such a list can be replenished endlessly. After all, it is with the development of progress that forged elements can be useful for anything. What makes them popular is not only the strength of the material, but also its elegant appearance.

Due to such a great demand for forged products, one can’t help but wonder why people like elements of artistic forging so much. After all, metal is a cold, heavy material that is subject to corrosion in the environment. In contrast to these negative factors, there are many favorable ones:

1. Durability.
2. Exquisite beauty.
3. Increased protective functions.
4. Possibility of production according to any dimensions and sizes.
5. Full possibility of imagination in manufacturing.
6. Forged products combine well with other materials.

And this is not the entire list of advantages of forged elements. If we combine all the above expressions, then metal objects are durable, strong and very beautiful products.

Disadvantages of metal elements

No matter how good people say about forging, there will always be bad things. Moreover, in this case, the disadvantages force many people to abandon forged elements and products.

Of course, the main and main disadvantage is the price. The fact is that most of such work takes a lot of time and effort. In addition, various expensive machines and the cost of the metal itself play a role. For example, if you compare a regular fence made of profiled sheets and the same fence with forged elements, the price can almost double or even triple.

The next and final disadvantage of forging is its susceptibility to corrosion. No matter how well the material is processed, the metal will always be poorly affected by humidity and dampness.

Types of products

If we consider the types and styles of forging, they offer enormous scope for creativity. This is one of the main advantages. You can make both simple and strict products, and more complex ones with elements of special bending and design. Whatever the type of product, it is always easy to combine and install with other building materials and architectures. According to the method of work, forging is divided into two types:

Despite the fact that both options provide the same product in structure, they differ greatly in price and features.

Cold forging

It is performed without heating the metal and, accordingly, is subjected to greater mechanical pressure. Usually they use special machines for cold forging, but there are cases when cold forging is done with your own hands in various homemade ways. There are several advantages of the method:

1. Lower cost compared to hot.
2. Availability of elements.
3. Possibility to combine patterns using welding.
4. More convenient possibility of making it yourself.
5. Less exposure to work hazards.

Objectively speaking, you can find a negative side. Let's note a few disadvantages of the work:

1. Restrictions on working with elements.
2. More standard and geometric types of work.

We can confidently say that cold work will completely replace hot work in terms of price.

Hot forging

This type of forging was invented long before cold forging. After all, previously there were no powerful machines and other devices to bend metal without heating. However, this type is much more practical than the cold one.

When heated, the metal becomes more ductile, which means it is better able to stretch, compress and bend. When working with hot metal, you can make a more complex element than with cold metal.

Corrosion of metal

Metal corrosion is one of the important factors affecting the product. Elements of artistic forging of metal should be treated with painting oils so that corrosion does not appear for a long time.

On more expensive products, a special metal cleaning machine is used before painting. Despite the cost of such work, this is one of the best means for cleaning metal from rust and corrosion.

If the budget allows for expensive metal cleaning work, then you can afford expensive painting. Typically, for such work, zinc-containing oils are used, which can penetrate the top layer of metal and prevent moisture from affecting it.

Painting of forged products

Any metal product requires a primer before painting. If you do not take such actions, then even the most expensive paint will lose its properties. The thing is that any primer has corrosion resistance and adheres better to the metal. This is why the paint will adhere more firmly to the primer than to bare metal.

Cheap primer and paint will not give the desired effect for forged elements. After their application, the paint quickly fades and peels off the coating.

There are special types of paint - “3 in 1”. They have the combined properties of a primer and paint. Typically, such materials are much more expensive, but when using them you will not need to spend money on a primer.

What is needed for forging

If you pay attention to hot forging, you simply won’t be able to do this type of work yourself without the proper skills and equipment.

However, there is also a cold type of work that many people do without professional training. For most of such work and the production of simple decorative elements, special machines are not required.

Many hobbyists make similar machines from improvised materials. In principle, homemade equipment is not very different from professional equipment, but has less developed functionality.

When working in cold weather, do not forget that you will need very serious physical training. In addition to endurance, you will need tools such as:

1. Welding machine.
2. Bulgarian.
3. Hammer.
4. Anvil.
5. Various processing tools.

To operate a welding machine, you will need welder skills. Since forged products most often require accuracy and strength, the specialist’s skills should be far from being at the initial level.

When working with an angle grinder, considerable experience will also be required. After all, this is a rather dangerous tool if handled incorrectly. And also do not forget about safety precautions and wear safety glasses.

A hammer and anvil are the main thing when working with forged elements. There will always be something that needs to be corrected or straightened if it is bent incorrectly.

Processing materials include brushes, sandpaper, files and more. To make your elements look neat and beautiful, each welding seam should be well processed.

Source: https://sotka.guru/kak-eto-sdelat/metallicheskie-izdeliya-svoimi-rukami-iz-elementov-holodnoy-kovki.html

DIY forged products: types of forged products, how to make a similar product with your own hands - Machine

If you have purchased a plot of land, be it a house or a dacha, the question of registering the plot always arises. One of the most beautiful pieces of jewelry that shows the owner’s self-sufficiency and good taste is forged items. It can be either just a forged barbecue or entire compositions of forged products.

From forged metal you can make gazebos that are striking in their beauty; a bench or staircase will fit perfectly into any interior. Forged fences are made, even balconies. You can make a railing on the porch.

Today you can make all this beauty yourself; it is not difficult, as it might seem at first glance. The fact is that these things can be created without resorting to the services of a forge. You can use DIY cold forging machines right at home. And photos of forging clearly illustrate the results.

Types of forging machines

For cold forging work, special machines are used. Moreover, each curl or bend requires its own machine for cold hand forging. They are:

• With manual drive;
• Electrically driven.

The first ones are used when it comes to small amounts of work. They are easier to create. Their downside is low productivity. Drawings of a forging machine with your own hands will clearly show the entire process of their assembly.

The latter will be necessary if we are talking about the continuous production of forged products. They have much higher productivity, and do not need to exert physical effort - the drive is carried out by an electric motor.

For those who are just taking their first steps in making forged items, it makes sense to start with a machine called “Snail”. A do-it-yourself forging snail will be an excellent assistant when making a gate and a bench.

If the first steps have been completed and there is an interest in developing the chosen direction, you need to move on to mastering the torsion bar machine. With it you can achieve the use of non-standard approaches to the execution of forged products. Your things will acquire individuality - you can diversify the products produced.

Cold forging stages

• Although the process of making forged items is very exciting, you need to remember that this process must be carried out in a certain sequence.
• To understand the sequence of technological actions, you need to know the stages of forging or the elements of forging yourself:

• Draft.
• Broach.
• Firmware.

The draft is necessary to increase the existing metal workpiece from the side by reducing the height. It is performed under fairly high pressure.

Broaching reduces the cross-section and increases the length. The workpiece needs to be heated, then “passed” with a hammer.

Piercing is the creation of holes inside a workpiece. The holes in the workpiece itself can be made of different sizes and diameters.

After the stages of upsetting and broaching, the structure of the item becomes more fragile. It is important to take this into account in the future and be extremely careful when working with the product, since the item can simply be broken.

Step-by-step instructions for forging

All forged items can be made with your own hands right at home. It will not be possible to make special patterns, however, you can make all the basic elements yourself. It is important to follow all stages and technology.

There are several technological stages:

• Checking all calculations. Even minor inaccuracies can spoil the entire final result. Correcting errors will be very difficult, and often impossible.
• Assembling a decorative composition.
• The elements are fastened together by welding. However, it is important to remember that it can cause damage to small decorative elements.
• Processing of the resulting product - by sanding and painting the entire resulting product.

Disadvantage of cold forging

The only disadvantage of cold forging is the inability to correct errors during the process. If the workpiece is damaged, then it will have to be thrown away, at best, as scrap metal, or kept as a souvenir and used for training in the future.

The whole point of cold forging is that the metal is not heated, but is bent by processing in a “cold” form. This is how the metal is given the desired shape.

The advantage of cold forging is the absence of the need for special equipment, as well as the absence of the need to use fire-hazardous equipment; the manufacturing conditions are acceptable for any person with any health. The use of high temperature conditions is not required.

DIY forging photo

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Metal forging

Processing a metal part by changing its shape and size is called metal forging. As a result of forging, the metal is deformed and changes its parameters. There are hot and cold forging. Can be done with your own hands.

During hot forging, the metal is heated to the so-called forging temperature, it is different for different materials, for steel it is 800 - 1200 ºC, for copper alloys - 650 - 1000 ºC, for titanium and its alloys -900-1600 ºC, aluminum is deformed at temperature — 400-480 ºC.

Cold forging, that is, metal processing without preheating, is also widely used.

It should be noted that the widespread use of rolling and stamping equipment and the use of computer equipment has displaced forging from heavy industry. But, nevertheless, forging is used to create fences, jewelry, locks, knives, and weapons.

Nowadays the cold forging method is popular. Its use allows for savings on the maintenance of production space; with the widespread introduction of cold metal processing technology, there is no need to operate energy-consuming equipment, for example, a forge.

Previously, hot forging was the main method for the production of forged parts and products.

Parts and products obtained by forging are called forging

Hot forging

The metal is heated in a furnace to a temperature at which it loses its strength and becomes plastic. Next, the metal workpiece can be processed using impacts and other methods.  

But heating the metal has disadvantages:

1. The workshop must be equipped with a forge or muffle furnace. This requires installation costs, equipment maintenance and fuel purchases.
2. It is necessary to take safety measures, because forging metal involves the presence of open fire.
3. The specialist must have certain knowledge and skills in hot metal processing.

Forging methods

1. Manual;
2. Stamping;
3. Forging with hammers.

Forging is carried out using hand or mechanized tools. This can be either a sledgehammer or a press powered by different types of drives, for example, pneumatic.

This operation allows you to obtain parts with different dimensions, weights and shapes.

The use of forging increases the mechanical parameters of steel and improves its internal structure. That is why especially critical parts are processed using the forging method. For example, connecting rods installed on internal combustion engines.

Forging is divided into two large groups - hand and machine. For the first, a hand-held percussion tool or specially manufactured forging and pressing equipment is used. Presses and hammers are used for machine processing. Heavy and large parts are processed on presses, smaller parts are processed on mechanical hammers.

Hand forging should only be carried out in a specially equipped workshop. In addition to the heating forge, the workshop must be equipped with a ventilation system and an anvil. It is a significant piece of metal on which technological devices, for example, a horn or a matrix, can be mounted to produce calibrated parts. For the production of anvils, 45L steel is used.

With the help of an anvil, the forging of blanks is done by hand and gives them the desired shapes and sizes. Having a flat surface on the anvil allows you to machine flat parts.

Metal processing using impacts is divided into free forging and processing in dies.

The essence of free forging is to enclose the workpiece between the hammer (press) and the base. The required shape and dimensions are obtained by the machine operator using an auxiliary tool.

During stamping, the metal receives the shape and dimensions within the limits of the tool used for processing. To release the part, a new stamp is required. Stamping is an intermediate technological operation, after which the resulting semi-finished products are sent for additional processing, such as welding or drilling.

Forging equipment

Forging and pressing machines are widely used in industry. It is divided according to the following characteristics:

1. According to the temperature of the workpiece being processed. For this technological operation, I use forging machines that can process both cold and heated workpieces. Machines of this class are used for processing flat and three-dimensional parts.
2. According to the operations that can be performed on this equipment, that is, for procurement, main and finishing operations.
3. According to the method of feeding or removing finished products from the working area of ​​the machine, in practical work they try to use devices for automatically feeding and removing workpieces and waste.
4. By type of drive, it operates from different types of drives - electricity, compressed air, hydraulics.
5. According to the main characteristic - the nominal force exerted by the press at the working moment.

Hot Forging Tools

Forge, anvil, sledgehammer and handbrake, pliers, shaped hammers, shperaks.

Induction heaters

Before sending a workpiece for processing using hot forging, it is necessary to ensure that it is heated to a certain temperature. This problem is solved using heating devices. As already mentioned, a forge or muffle furnace is used for heating, but there is another type - induction heaters. Parts pass through these devices and will be sent to stamping and forging operations.

Advantages of heating in an induction furnace:

• reducing the cost of electrical energy and this is especially important during a time of constant increase in tariffs.
• increase in work productivity, since heating workpieces in this way allows you to reduce the time required to heat the part.
• allows not only to accurately position the workpiece in the oven, but also to optimally position it for more efficient heating.
• no scale remains on the surface of the workpiece and this has a positive effect on the use of stamping and forging tools. This frees up production space.

Artistic forging

Used for the production of small-sized and elegant objects. Artistic differs from traditional in that it is not only a method of metal processing, but a kind of art. Quite often, parts obtained using artistic forging are used when decorating premises.

Craftsmen who engage in artistic forging are able to produce a variety of products that can fit into any interior. It should be noted that the demand for such things is constantly growing and this is an interesting place for business development.

Source: https://prompriem.ru/metalloobrabotka/kovka-metalla.html

What is metal forging - Metalworker's Handbook

07 October 2013, 14:52

Forging itself, as an ancient method of metal processing, arose during the founding of the first states - Iran, Mesopotamia, Egypt; forging was used by the Indians of North and South America and other peoples.

The art of metal processing was one of the signs of statehood.

https://www.youtube.com/watch?v=cwKi5SwEF7E

First of all, forging was used in the manufacture of weapons, household items, and tools; artistic forging appeared much later.

A little history

From the 14th-15th centuries, the spread and gradual popularization of artistic forging began, which became a luxury item that not everyone could afford.

With the development of trade and technical crafts, artistic forging is becoming increasingly expressive, especially in Germany and France. Italy, Czech Republic. Architectural metal reached its peak during the Renaissance, during the creation of landscape gardening ensembles.

The main customer for the blacksmiths was the church. At all times, the blacksmith always worked under the strict guidance of the architect. The concept of an artist-blacksmith was completely absent.

Forging during the Baroque period became more intricate, it was distinguished by a complex alternation of elements, a large number of curls, and it looked very magnificent. The Rococo era finally changes the appearance of forging - symmetry, abundance, and accumulation of elements disappear in it; Rococo is characterized by plant motifs and filigree.

In Ancient Rus', blacksmiths enjoyed special respect. They made swords, helmets, chain mail, shields, horse harness decorations, and together with jewelers they created stunningly beautiful jewelry.

With the development of cities, blacksmithing became widespread; blacksmithing cartels were created in cities in Rus'.

Artistic forging was widely used in the architecture of palaces under Peter I, who was an ardent supporter of change and an adherent of European culture.

Then, having gained a strong position, forging as a decorative element was steadily used in architecture. In the 20th century in the Soviet Union, forging gave way to casting (primarily this is due to the development of rolling and stamping production).

Nowadays

Currently, artistic forging is again gaining popularity, and now it is literally entering our home - in the form of interior items and landscape design. Along with the manual labor of blacksmiths in art workshops, products are manufactured using industrial methods.

The greatest demand among forged furniture are beds, benches, tables, chairs, fireplace accessories, hangers, flower stands, shelves, consoles, lamps, chandeliers, sconces, as well as various accessories.

Forged gates, balcony and lawn fences, gazebos, pavilions, arches, bridges, and garden benches are widely used in landscape design.

Accessories are also interesting - forged flower stands, stands, door handles, figures for the garden.

The choice of forged products requires a sense of style, because forging has polar properties - it can be either very elegant, modern, or “heavy”, archaic. A landscape designer will help you with the choice of artistic forging; in addition, many companies offer to make forged products to order.

Manufacturing process

Forged products, like many centuries ago, require great skill and diligence.

They are born as a result of long and painstaking work: first, designers create and refine a sketch to the smallest detail, then carry out computer modeling.

And only then, after agreeing on all the nuances with the customer, the craftsmen begin the mystery of transforming cold and shapeless metal into amazing works of art.

Disparate forged elements are combined into a single composition, forming complex patterns, intricate ornaments, and openwork. Modern machines and equipment allow you to reproduce a design of any complexity that your imagination is capable of.

One of the varieties is cold forging - in which the product is not heated, but processed with hammers and other tools. It is believed that cold forging is preferable because it does not affect the metal at high temperatures, which supposedly makes it stronger.

Forged gates

Forged gates are in great demand. They can be built into a wall or gate or located separately. The choice of a forged gate is very important, since the gate is the first thing people see when approaching the house.

Fully forged fences are very common in European gardens; in our country, a combination of materials is more often used. Forging looks very beautiful with stone. The combination of forging and wood creates the feeling of a real medieval gate.

Forged products are coated with paint of different colors, their height can also be different - from 1.5 to 3 or even 5 m.

Wrought iron furniture

Forged tables can be chosen in different designs, they come in different colors and sizes, and can combine different materials (combination with wood is a classic option, forged tables using glass are distinguished by the Art Nouveau style).

Forged benches, as a rule, also represent a combination with wood, although there are also completely forged benches. A wrought-iron bed is what will be the highlight of your bedroom interior.

Forged furniture is an excellent choice, because it is durable, stable, and very beautiful.

Forged arches and pergolas

Forged arches and forged pergolas are used to create corridors in a summer cottage; they are used for zoning a garden; they often serve as a support for climbing plants on the site. Forged arches and pergolas will highlight the beauty of flower beds and ponds.

Forged lanterns, lamps

The advantage of forged lanterns and lamps is that they fit well into different architectural styles.

Tall wrought iron lanterns create a romantic mood; sometimes they look a little old-fashioned, which gives the garden a special charm. Forged lanterns can also be attached to the walls of the house.

Small forged lanterns and lamps can be placed in a rocky garden or placed near a pond.

Forged accessories

The size of a summer cottage does not always allow for the placement of large forged products, so you can limit yourself to forged accessories. These can include forged figures for the garden, forged flower stands, door knockers, and umbrella holders.

Caring for forged products

Forged products are durable. Typically, manufacturers provide a warranty of 5-7 years.

However, while forged items in the interior do not require special care, forged items in the garden that are exposed to adverse weather conditions need to be looked after.

Once every two to three years, it is recommended to apply powder coating or refresh the paint. Also, do not forget to lubricate the moving mechanisms of forged gates and gates.

In recent years, artistic forging has seen an active revival.

Source: https://ssk2121.com/chto-takoe-kovka-metalla/

Interesting about metal forging

Interesting fact, one of the most common surnames in the world comes from blacksmithing. This is Kuznetsov in Russia, in France - Ferrand, in Britain - Smith. This indicates the prevalence of this craft throughout the world.

blacksmith craft

The basis of the word deceit is the verb forge. The fact is that many peoples and tribes considered blacksmithing to be obscure and shrouded in mystery. Kovar (blacksmith) makes forges, knits shackles, so over time the noun cunning denoted wisdom, skills, ability. Over time, it began to mean evil plans and intentions. At the same time, the phrases “forge your happiness” and “forge your destiny”, which have a positive meaning, also appeared.

During the mass unification of production and the use of equipment such as rolling, stamping, the use of computer control practically displaced blacksmithing from heavy industry, but it remained and is popular with designers and interior design specialists. Modern blacksmiths make products that are used to create fences, stairs, architectural design of buildings, etc.

Rolling equipment for cold forgingHot stamping

But our century has led to the fact that the design of forged products is carried out using special 3D design programs intended for the development of parts for various purposes.

Open forging is used on a variety of metals. With the help of this operation, both household items and objects of artistic value are performed. By the way, this method of metal processing is also used in jewelry. In fact, the most malleable metal is gold. It has plasticity, fluidity, ductility and many other properties that make it possible to obtain priceless products from it.

Jewelry forging

In practice, two main types of forging are used - hot and cold.

Basic methods of forging metal

Free forging of metal can be done when the metal is heated to a certain level. This method is called hot forging, and until recently it was the main method of producing forged parts.

Over the past few decades, cold forging has become increasingly popular. This method is distinguished by the fact that its use allows saving on production space, eliminating the need to maintain an energy-consuming forge, etc.

As already noted, hot forging is possible when the metal is heated to temperatures at which it changes its strength characteristics and acquires plasticity, which makes it relatively easy to process using impact tools and various devices. Hot metal processing involves the use of certain metal processing technologies that allow a variety of finished products.

Meanwhile, heating the metal also has certain disadvantages. Firstly, heating the metal means that a forge or muffle furnace must be installed in the workshop.

It should be immediately noted that the presence of such equipment implies the presence of costs for its maintenance and fuel. Secondly, the use of open fire is an unsafe activity and requires the master to observe increased safety measures.

Thirdly, hot forging requires that the master have certain knowledge and skills regarding the temperature parameters of the metal.

Hand forging of metal must be performed in a specially equipped workshop. The list of equipment includes the following equipment and devices:

• forge or muffle furnace;
• air exhaust system;

An anvil, which is a solid-sized (weighing up to 250 kg) metal pig, which may have such technological devices as horns and calibrated holes. For its manufacture, 45L steel is used.

On an anvil, you can forge metal with your own hands and give heated workpieces the required shapes and sizes.

In addition, there is the possibility of forging a sheet on the surface of the anvil.

Cold forging method

Most cold forging work is performed on equipment specially designed for this purpose. You can name a certain list of equipment that is used for cold metal processing. As a rule, such equipment shows its effectiveness when performing large volumes of work in the architectural design of buildings and structures.

Among the equipment used in the production of cold forging products are the following:

• torsion bar, it is used to twist the rod along its axis;
• wave, various wave-like parts are made on it.

In total, the fleet of cold forging equipment includes about a dozen units. Some are powered by the operator's muscular strength, some are powered by an electric drive. Some craftsmen are engaged in the independent production of such equipment.

Types of blacksmithing

Forging is performed using manual or mechanical impact tools, this could be a sledgehammer or a press, which can be powered by an electric, pneumatic or hydraulic drive.

Forging and stamping provide the production of parts that have different overall weight parameters and shapes.

The use of forging leads to an increase in the mechanical parameters of steel and optimizes its internal structure. That is why critical parts, such as connecting rods, are produced using free forging or stamping. Forging can be divided into the following types - hand and machine.

For the first, a hand-held percussion tool (hammer, sledgehammer, etc.) is used; all metal processing work is performed on an anvil. The second type of forging is performed on forging equipment equipped with a hammer, etc.

When machining, heavy and bulky workpieces are processed under pressing equipment, and smaller ones with less weight are processed with a hammer.

Metal processing by impact can be divided into free forging and die processing. Free forging involves the workpiece being compressed between a press and a base. The formation of the finished part occurs due to the auxiliary tools used by the blacksmith.

Blacksmithing

When stamping, the metal takes on the shape and dimensions within the tool die. To produce a separate part, a new die must be made. In fact, forging and stamping are intermediate technological operations that lead to the production of workpieces, which will subsequently undergo additional processing, for example, milling or welding.

Types of modern forging equipment

A variety of forging and stamping equipment is widely used in industry. It can be classified according to the following parameters:

• according to the temperature of the workpiece being processed. For this operation, forging machines and equipment for hot and cold stamping, both flat and volumetric, are used;
• on operations performed on equipment. Divide the procurement, main and finishing CSW;
• according to the method of supplying and removing finished products from the workspace of the KShO. In practice, equipment is used on which all these operations are performed manually, in semi- and automatic mode.
• by type of drive. Presses and stamping machines operate on electricity, compressed air, hydraulics, etc.
• by key parameter. As a rule, this is the nominal force created by the press or operating torque.

Before processing by hot forging, the workpieces are heated to a certain temperature. To solve this problem, various heating equipment is used. This list also includes induction heaters. They preheat the workpiece before stamping, bending, forging, etc.

This form of heating has a number of advantages over other types, for example, gas or electric.

In particular:

• • the use of induction heaters leads to a reduction in energy costs and this is quite important, especially in conditions of stable growth of tariffs;
  • the use of heaters increases labor productivity, since induction heating allows minimizing the time spent warming up the part;
  • in automated furnaces, due to the accuracy of positioning and arrangement of workpieces in the inductor, heating accuracy increases;
  • heating the workpiece in an induction furnace is characterized by a small amount of scale and this has a positive effect on the service life of the stamping tool;

• Installing such equipment allows you to free up additional space in the production facility.

HDTV induction heater

Source: https://stankiexpert.ru/spravochnik/obrabotka-davleniem/kovka-metalla.html