Smithy Shope

Contents
1. Introduction to forging
2. What is forming
3. Bulk Deformation Processes
4. Forging
5. What is Recrystallization temperature ?
6. Difference between hot forging and Cold forging?
7. Smithing Forging Operations
8. Tools and Equipments used in forging
9. Defects of Forging.
 What is Forming ?
Forming is the process of obtaining the required shape and size on the raw material by subjecting the material to
plastic deformation through the application of tensile force, compressive force, bending or shear force or
combinations of these forces.
Introduction to Forging
Deformation Processes
When shaping materials into finished products,
we use two types of deformation processes:

Bulk Deformation Processes

[Link] involve shaping materials where the
surface area to thickness ratio is small (thick
parts).
Examples: Billets
Ingots
1. Primary forming: Converting large
cast metals (ingots) into semifinished
raw materials like blooms or billets.
Example: Rolling a large steel ingot into
rectangular billets. spanners
2. Secondary forming: Using
semifinished raw materials (like billets)
to create finished parts
Example: Forging billets into spanners, Gears
gears, or railway wheels. Railway wheels
Introduction to Forging
Sheet Metal Forming Processes
These produce parts with a large surface area to
thickness ratio (thin parts).
Key requirement: Thickness variation should be minimal
to maintain part quality.
Examples:
beverage cans
1. Making beverage cans from thin aluminum sheets.
2. Shaping car body panels for vehicles.

Car body panels

Bulk Deformation Processes
The main bulk forming processes include:

Rolling
[Link]: Metal is passed between two rollers to
reduce thickness and make sheets, billets, or
blooms.
[Link]: Rolling steel to make sheets for
Rolling steel
construction or machinery parts.

Forging
[Link]: A metal is compressed under high
pressure to shape it.
2. Example: Forging a crankshaft for an engine.
 Bulk Deformation Processes
Extrusion
[Link]: Metal is pushed through a die to create long
shapes with constant crosssection.
[Link]: Making aluminum rods or pipes.

Drawing
[Link]: Metal is pulled through a die to create wires
or thin rods.
[Link]: Drawing copper to make electrical wires.

Extrusion Video
Forging
Forging is a process used to shape metal into specific objects
(like coins, jewelry, weapons, and tools) by applying
compressive force. This force makes the material change its
shape. The process can be done in three ways:

Hot Forging: This is done when the metal is heated to high

temperatures (above 60% of its melting point). When the metal
is hot, it is easier to shape, and the process needs less force.
However, it can handle high strain rates and can create parts Hot Forging
that are strong but not too brittle.

Warm Forging: In this process, the metal is heated to a

medium temperature (between 30% to 50% of the melting
point). It’s still easier to work with than cold forging, but it
requires more precision and a bit more force than hot forging.

Cold Forging: This is done at room temperature. Cold forging

is great because the parts produced have a high surface finish
(they look smooth and polished), high strength, and they need
little extra machining after forging. However, it requires more
force than hot forging, and the material might be harder to
shape.
Cold Forging
What is Recrystallization temperature ?
The recrystallization temperature in
forging refers to the temperature at
which the internal structure of a metal
undergoes recrystallization, allowing
new grains to form, replacing the
deformed ones created during plastic
deformation. This process helps to
restore ductility and reduce internal
stresses in the material.
Difference between Hot Forging & Cold forging
Difference between Hot Forging & Cold forging
SMITHING FORGING OPERATIONS
 SMITHING / FORGING OPERATIONS
1. Upsetting
Upsetting is a forging process used to make a part of a workpiece thicker or increase its diameter by reducing its length through
hammering. Here's an easy explanation:
Purpose: To increase the thickness (or diameter) of a specific part of the workpiece.
Process:
Heat the workpiece in a furnace to make it soft and easy to deform.
Keep only the part to be thickened hot while cooling the rest by dipping it in water to prevent unwanted deformation.
Hold the workpiece firmly with tongs at one end.
Place the other end on the flat surface of the anvil.
Hammer the heated (softened) part to increase its thickness.
Applications: Upsetting can be done on:
The ends of a workpiece,
The middle part, or
The entire length, depending on the design requirements.
This technique is widely used to strengthen specific sections or to prepare parts like rivet heads, bolts, and flanges.
1. Upsetting
 SMITHING FORGING OPERATIONS
2. Drawing Down
a. Purpose: Drawing down is a forging operation used to reduce the thickness or
diameter of a metal piece while increasing its length.
b. Process:
The metal piece is heated until it’s hot and malleable.
Place the hot piece on an anvil and hold it firmly with a tong.
Use a straight peen hammer to strike the metal, which gradually stretches it out,
making it thinner and longer.
Tools Involved:
Fullers: These are tools with curved or rounded edges. Fullers can be used to help
reduce the metal’s thickness quickly by concentrating force on specific areas.
a. One fuller is placed in the square hole of the anvil.
b. The hot metal is placed on top of the fuller.
c. A matching fuller is held on top of the metal, and the head of the fuller is
struck with a hammer.
Finishing: After fullering, use a flatter (a tool with a flat bottom) to smooth and
flatten the surface of the metal piece.
 SMITHING / FORGING OPERATIONS
Bending is a common forging operation used to give a curved shape to a
workpiece. Here's an easy explanation:
Purpose: To shape the workpiece into a bend or curve, commonly done in
workshops.
Process:
1. Place the workpiece on the edge of the anvil, anvil horn, or another support.
2. If working with a thin rod or bar, you can insert one end into a hole and bend it
using a wrench or tongs.
3. When bending, the metal fibers inside the curve are compressed (shortened),
while those on the outside are stretched (extended).
Precautions:
1. Bending may cause thinning at the bent section. To prevent this, you can use a
small upsetting process (thickening) at the area to be bent before starting.
2. The process takes some time as precision is needed to avoid weakening the
workpiece.
3. This method is commonly used to create hooks, clamps, and other curved
shapes.
 SMITHING FORGING OPERATIONS
Punching and Drafting Operations

Punching and drifting: Punching means an operation in

which a punch is forced through the workpiece to produce
a rough hole. The job is heated, kept on the anvil and a
punch of suitable size is forced to about half the depth of
the job by hammering. The job is then turned upside down
and punch is forced in from the other side, this time
through and through.
Punching is usually followed by drifting i.e, forcing a drift Punching
in the punched hole through and through. This produces a
better hole as regards its size and finish.
Both operations are important for creating holes and slits
during metalworking, ensuring accurate shaping for
assembly or design purposes.
 SMITHING FORGING OPERATIONS
Surging:
Purpose: This operation is used to refine and shape an already deformed workpiece into a desired shape and size, such as
round or hexagonal forms.

Fullering and Flattening:

1. Fullering:
Purpose: To reduce the thickness of a heated workpiece.
Tool Used: A fuller tool, consisting of a top and bottom fuller.
Process:
The bottom fuller is fixed in the hardie hole of the anvil.
The workpiece is moved between the top and bottom fullers, creating corrugations or grooves.
Additional Use: Fullers of smaller diameters can be used to convert flat rods back into a round shape if required.
 SMITHING FORGING OPERATIONS
2. Flattening:
Purpose: To smooth out the corrugated (shaped into folds)
surface created by fullering.
Tool Used: A flatter tool and a hammer (or a set hammer).
Process:
Place the corrugated workpiece on the anvil.
Strike it with the flatter tool and hammer to achieve a
smooth, flat surface.

Note: Fullering is always followed by flattening to achieve

the final desired shape and surface finish.
Fullering : technique used to shape and stretch metal by
creating grooves or indentations. It involves using a
specialized tool called a fuller, which has a curved or
rounded surface.
 Cutting (Hot Cutting or Chiseling)
This process is used to cut a workpiece into desired sections using a hot chisel. The following explains it in simple steps:

1. Heating the Workpiece:

The workpiece is heated to a light cherry red hot temperature, typically between 800°C to 900°C, in the furnace.
Heating ensures the material becomes soft, making it easier to cut.

2. Using a Hot Chisel:

The chisel has a cutting edge angled at approximately 30°.
It is positioned over the area to be cut on the redhot workpiece.

3. Hammering the Chisel:

A hammer strikes the chisel, driving it into the heated metal.
The force and sharp edge create a clean cut as the softened material gives way.
This process is commonly used in smithy shops to divide or shape metal pieces, especially when cold cutting is not
feasible.
TOOLS AND EQUIPMENT USED IN
FORGING
 TOOLS AND EQUIPMENT USED IN FORGING
A forge is used for heating during forging operations. Its structure is made of cast iron or steel with four legs, a hearth
(bottom), a chimney, and a hood. A tuyere at the rear supplies air to the furnace, regulated by a valve. The hearth is lined with
fire bricks, and a water tank at the front is provided for quenching. Air is supplied by a blower, and forges are specified by the
size of the hearth or weight.
 TOOLS AND EQUIPMENT USED IN
FORGING
The anvil is a support device used in hammering
operations. It has a wrought iron or mild steel body
with a hardened steel face for general hammering.
The horn is used for bending and shaping curves,
while the chipping block supports cutting
operations.

The back has two holes:

[Link] Hole(square) – holds tools like swages
and fullers.

2. Pritchel Hole(circular) – for bending small rods

and hot punching.

Anvils rest on a cast iron or wooden base, typically

weighing 100150 kg and standing about 0.75 meters
tall.
TOOLS AND EQUIPMENT USED IN
FORGING
Bick Iron
A bick iron is a small anvil like tool designed
specifically for working on intricate or small metal
working jobs, serving a similar purpose to a fullsized
anvil. Made of durable tool steel, it features a tapered
shank that fits securely into the hardy hole of a
standard anvil during use. This allows for stability
while shaping, bending, or working on detailed metal
components.
TOOLS AND EQUIPMENT USED IN
FORGING
Swage Block
A swage block is a versatile block of cast steel used in
metalworking, particularly for squaring, sizing, heading,
bending, punching, and forming operations. It features a
variety of slots with different shapes and sizes along its four
side faces, as well as through holes of varying shapes and
sizes extending from the top face to the bottom face.
The swage block is typically supported on a sturdy cast iron
base for stability during use. It is specified either by its overall
size or by its weight, making it an essential tool for precision
metal forming tasks.
TOOLS AND EQUIPMENT USED IN
FORGING
Striking tools
 TOOLS AND EQUIPMENT USED IN
FORGING
Smith's Hammer
A smith’s hammer is a primary striking tool used in hand forging.
It is made of forged steel and is mainly used by the worker
(blacksmith) for shaping metal. The hammer has four key parts:
Peen:
The peen is the part opposite the flat face of the hammer. It is
usually pointed or rounded and is used for shaping, bending, or
peening the metal.
Cheek:
The cheek is the side of the hammerhead between the face and the
peen. It helps to provide balance to the hammer.
Eyehole:
The eyehole is the hole in the hammerhead where the handle is
inserted. It is crucial for securely attaching the handle to the
hammerhead.
Face:
The face is the flat striking surface of the hammer. It is the part
that makes direct contact with the workpiece when hammering.
 TOOLS AND EQUIPMENT USED IN
Tongs in Smithy Work FORGING
Tongs are essential tools used to hold and manipulate the
workpieces during forging. They are generally made of mild steel
and consist of two pieces riveted together to form a hinge. The
tongs have two main parts:

1. Jaws: These are the parts used to grip and hold the workpiece.
They come in various shapes and sizes to accommodate different
types of workpieces.

2. Arms: The longer portion of the tongs, used to apply pressure

for gripping and moving the workpiece. The movement of the
jaws is controlled by applying hand pressure on the arms.

Tongs are typically specified by the length of the arms and the
shape of the jaw openings.
 TOOLS AND EQUIPMENT USED IN
Types of Tongs FORGING
1. Flat Tong
These tongs have jaws with a rectangular section and are
used for holding flat workpieces.
2. Straight Lip Fluted Tongs
These are used for holding workpieces with circular, square,
or hexagonal sections.
3. Ring Tong
These tongs are specifically designed for gripping circular
workpieces, such as rivets, bolts, and other similar items.
4. Gad Tong
These tongs are used for picking up and holding straight or
tapered workpieces.
TOOLS AND EQUIPMENT USED IN
FORGING
TOOLS AND EQUIPMENT USED IN
FORGING
TOOLS AND EQUIPMENT USED IN
FORGING
Defects of Forging
1. Mismatched forging
Reasons
Due to non alignment of proper die halves.
2. Brunt and overheated metal
Reasons
This is caused by improper heating the metal at high temperature or for a long time.
3. Fibred flow lines discontinued
Reasons
This will occur because of very rapid plastic flow of metal.
4. Scale pits
Reason
These are formed by squeezing of scale into the metal surface during forging.
5. Oversize components
Reasons
Due to worn out dies, incorrect dies, misalignment of die halves.