Basic Metal Works

Level-I

Learning Guide#50
Unit of Competence: Perform Hand Forging
Module Title: Performing Hand Forging
LG Code: IND BMW1 M15 LO1-LG-50
TTLM Code: IND BMW M15 TTLM 1019v1

LO1: Analyze and plan hand forging work

Page 1 of 67 Federal TVET Agency TVET program title:-Basic metal work Version -1
Author/Copyright Level -I October 2019
 Instruction Sheet Learning Guide #50

This learning guide is developed to provide you the necessary information regarding the
following content coverage and topics:
 Interpreting drawing for swaging, bending, upsetting, spreading, punching and drifting
techniques
 Selecting Hand tools and formers
 Applying forging temperatures and heat specifications
 Drafting Work plan
This guide will also assist you to attain the learning outcome stated in the cover page.
Specifically, upon completion of this Learning Guide, you will be able to:

 Interpret drawing for swaging, bending, upsetting, spreading, punching and drifting
techniques is in compliance with specification.
 Select Hand tools and formers for required forging techniques.
 Apply forging temperatures and heat specifications to for various materials
requirement
 Draft work plan according to specifications
Learning Instructions:
Learning Instructions:
1. Read the specific objectives of this Learning Guide.

2. Follow the instructions described below.

Read the information written in the “Information Sheets”. Try to understand what are being
discussed. Ask your trainer for assistance if you have hard time understanding them.

3. Accomplish the “Self-checks” in the information sheets.

4. Ask from your trainer the key to correction (key answers) or you can request your trainer
to correct your work. (You are to get the key answer only after you finished answering the
Self-checks).
5. If you earned a satisfactory evaluation proceed to “Operation sheets and LAP Tests if
any. However, if your rating is unsatisfactory, see your teacher for further instructions or
go back to Learning Activity.
6. After you accomplish Operation sheets and LAP Tests, ensure you have a formative
assessment and get a satisfactory result;

Page 2 of 67 Federal TVET Agency TVET program title:-Basic metal work Version -1
Author/Copyright Level -I October 2019
7. Then proceed to the next information sheet.
8. If you earned a satisfactory evaluation in each self-check proceed to “Operation Sheets”
in pages. However, if your rating is unsatisfactory, see your trainer for further instructions
or go back to Learning Activities.
9. Read the “Operation Sheets” and try to understand the procedures discussed.
10. Do the “LAP test” in each page (if you are ready). Request your teacher to evaluate your
performance and outputs. Your teacher will give you feedback and the evaluation will be
either satisfactory or unsatisfactory. If unsatisfactory, your teacher shall advice you on
additional work. But if satisfactory you can proceed to Learning Guide.

Page 3 of 67 Federal TVET Agency TVET program title:-Basic metal work Version -1
Author/Copyright Level -I October 2019
 Information Sheet-1 Interpreting drawing for swaging, bending, upsetting, spreading,
punching and drifting techniques

INTRODUCTION

 Forging is a type of metal Forming Processes by means of localized compressive forces

exerted by manual or power hammers presses or especial forging machines. Forging is
one of the oldest metal working operations known, dating back to 5000 (4000) B.C. and is
used in making parts of widely varying sizes and shapes from a variety of metals. In
forging, the shape of the raw material is changed by repositioning material rather than
removing it.
Among all manufacturing processes, forging technology has a special place because it
can be used to produce parts of superior mechanical properties with minimum waste of
material. During forging the atoms of the material will be packed so closely that some of
them will be broken into pieces and this causes the material to be strong that is metal flow
and grain structure can be controlled, so forged parts have good strength and toughness.

The raw material for forging is usually a bar, billet or blank. Forging is generally employed
for those components that require high strength and resistance to shock or vibration and
uniform properties.
Typical parts made by forging today are crankshafts and connecting rods, for engines,
turbine disks, gears, wheels, bolt heads, hand tools, and many types of structural
components for the machinery, transportation equipment and landing gear for aircraft.
FORGING METHODS

(1) Hand forging

(2) Drop forging
(3) Press forging
(4) Roll forging
 Hand forging: Hand forging is made by heating the metal until it is plastic state in an
open hearth furnace and there by hammering is done on anvil by smith/sledge hammer
with use of open face dies to get the desired shape and size by judgment of an individual.
 Drop forging: In this process of forming the desired shape by placing a heated bar or
billet on the lower half of the forging die and hammering the top half of the die into the

Page 4 of 67 Federal TVET Agency TVET program title:-Basic metal work Version -1
Author/Copyright Level -I October 2019
 metal by means of a power hammer by repeated blows the impact of which compel the
plastic metal to conform the shape of the die. This method is used to produce large
number of small and medium sized forging of similar parts.
 Press forging: In this process the heated billet is squeezed between die. The pressure is
applied by the forging press which completes the operation in a single stroke. Large
forging are generally shaped by thin method.
 Roll forging: Rolling involves the passing of a heated bar between revolving rolls that
contains an impression of the required shape. It is used to reduce short thick section to
long slender pieces.

 Forging

 Forgings the plastic deformation of metal by means of localized compressive

forces exerted by manual or power hammers presses or especial forging
machines.

 Forging is one of the oldest metal working operations known, dating back to
5000 (4000) B.C. and is used in making parts of widely varying sizes and
shapes from a variety of metals.

 The raw material for forging is usually

 Bar i.e. flat bar or solid bar

 Forging is generally employed for those components that require

 High strength and

 resistance to shock or vibration and

 Uniform properties.

 Forgings are metal parts that are given them shape by hammering or pressing.

 Most forgings are made of

 Steel but,

 brass;

 bronze,

 copper, and

Page 5 of 67 Federal TVET Agency TVET program title:-Basic metal work Version -1
Author/Copyright Level -I October 2019
  aluminum are also shaped by forging

 Typical parts made by forging today are

 crankshafts and connecting rods, for engines

 turbine disks,

 gears,

 wheels,

 bolt heads,

 Hand tools, and many types of structural components for the machinery,

 Transportation equipment and landing gear for aircraft.

 Forgings must usually be machined in the machine shop after they are forged

Advantages & Limitations of Forging

 Advantages of forging

 Usually have better mechanical properties, especially if the fiber flow lines are
directed.

 Can be held to within fairly close dimensional tolerances

 A wide range of forgeable metals is available.

 Forgings are readily welded & incorporated in welded structures.

 Limitations of forging processes

 Many intricate and cored shapes possible by casting processes can’t be

forged

 Usually forgings cost more than castings

 Closed impression dies for forgings normally cost more than patterns.

 Permanent molds, or die equipment needed for casting processes

 High tool cost and high tool maintenance

 Limitations in size and shape

 High tool cost and high tool maintenance and Limitations in size and shape

Page 6 of 67 Federal TVET Agency TVET program title:-Basic metal work Version -1
Author/Copyright Level -I October 2019
 1.2. Safety procedures

 Safety in Forging Shop

 Safe work practices and safe work habits result when you use
 Machines
 Tools and
 Materials correctly.
 You must follow commonly recognized safety rules and safety practices in order to
avoid possible accidents or personal injury.
 In forging shop you are working with
 Hot metal and there are so many moveable parts of machines used for shaping.
 Also forging machines operate at high speed and repeatable glowing movement.
 Therefore in forging shop one must take safety precautions into consideration.
 Hammers, trimming and press machines must have a protector for their working zone.
 Some of the causes of accident in forging shop are
 Fire: - burn might be caused by sparks.
 Sharp and pointed materials that can be considered as waste.
 Explosion: - sometimes the metal by itself explodes due to the presence of gas
pockets inside it.
 Noise: - Potential loss of hearing that can result from exposure to very high sound.
Thus it contributes to reduced workers performance.
Note: Most experts state that harmful effects can be expected from noise level
above 100 dB (decibel). Sound around 140 dB is physically dangerous and
increases muscular tension.
1.3. Safety Rules
 During forging operations,
 Burning injury,
 Damage of tools and equipment may occur due to lack of safe work habits.
 Safety habits must be developed to avoid or reduce accidents.
 Some of the safety rules of forging are:
a) Always use the tongs whose jaws fit to the shape of the forging piece.
b) Check that the heads of hand hammers and sledge hammers are fitted securely to their
handles.

Page 7 of 67 Federal TVET Agency TVET program title:-Basic metal work Version -1
Author/Copyright Level -I October 2019
c) Remove any scale with a steel brush or scraper; never use to clean the anvil with hands;
use protecting gauntlets.
d) Always clean the hot stock and anvil at interval of forging.
e) Observe that the anvil is free from wet and greasy materials.
f) Never try to forge cold or burnt metal.
g) Never allow any forging and waste materials to accumulate around the forging area.
h) Always keep the working area clean and tidy.
i) After completing the work, stop the air blast, and scrape the burnt coal (charcoal) from the
forge and extinguish the fire.
j) Put all tools equipment, devices and forging pieces in their proper places.

1.4. Drawing

 Drawing down
This process makes the metal thinner, by reducing its cross-section. Metal to be forged
is first hammered on the back of an anvil. The process can produce tapers that arc Hat,
circular, or square. Fig.1.1 shows the steps to follow in drawing down a circular taper:
1. Hammer four sides to produce a short square (Fig.1.1 (a)).
2. Lengthen the square taper (Fig.1.1 (b)).
3. Hammer the corners of the long square in step 2 to produce an octagonal shape
(Fig.1.1(c)).
4. Continue round all the corners in step 3 to obtain a circular end (Fig.1.1 (d )).
If the taper is fat or square go through either the first two or three stages above

 Avoid piping (hollow ends) when drawing down a taper.

Page 8 of 67 Federal TVET Agency TVET program title:-Basic metal work Version -1
Author/Copyright Level -I October 2019
Fig. [Link] in drawing down: 4 a) first stage short- square; b) second stage-long
square; (C) third stage- octagonal shape; (d) final stage- round shape.

Page 9 of 67 Federal TVET Agency TVET program title:-Basic metal work Version -1
Author/Copyright Level -I October 2019
Page 10 of 67 Federal TVET Agency TVET program title:-Basic metal work Version -1
Author/Copyright Level -I October 2019
Fig:- [Link] down

1.5. Twisting

 Twisting is one of the simple forge work operations.

 Which can be performed easily in the school workshop?
 It is essential to hear the metal properly for an effective
1. Mark the length to be twisted (Fig. 1.2(a)).
2. Heat the metal (nor very hot but red hot).
3. Place the bar in the vice (Fig. 1.2(b)).
4. Twist using specially prepared bars (Fig. 1.2.(c)).
5. Turn the bar using the two hands.
For a short sharp twisting, the metal must be very hot. However, a red hear along the
length required gives a long regular twist.

Fig.1.2. Twisting: (a) marked length; (b) holding work in vice (notice the position of the
marked line); (c) Twisting using a specially prepared wrench

Page 11 of 67 Federal TVET Agency TVET program title:-Basic metal work Version -1
Author/Copyright Level -I October 2019
Page 12 of 67 Federal TVET Agency TVET program title:-Basic metal work Version -1
Author/Copyright Level -I October 2019
1.6. Bending

Bending is flat stock. The question arises as to how long the flat stock is to be cut once the
stock is bent; the finished part will meet the dimension requirements. Finding the lengths of
the various parts when unfolded and laid- out in the flat is known as developing.
It should be noted that bending should take place at right angles to the grain direction, as
shown in fig. If the bending operation takes place parallel to the grain direction, separation
will occur and cracking will develop. Stock may be bent safely at angles up to 45 with the
grain direction. If there is any doubt whether a piece will bend without cracking, a test should
be run on the material to be used.
Since the neutral axis is not affected during bending by deformation, as this line remains
unchanged the length of the neutral bending line will give the true length of the piece after it
has been bent.

Fig.1.3. Bends at right angle and parallel to the grain direction

to have the exact size, the diameter of the neutral axis is usually taken with the internal
dimensions it is good practice to make a sketch and to convert all external dimensions to
internal dimensions before applying the equations.

Which follow the developed length on the neutral bending line for the bend shown in figure
[Link] La+b+a2, Where a = length of leg at neutral line, b = length of arc at neutral bending
line, al and a2 are under for mend parts of the part.

Page 13 of 67 Federal TVET Agency TVET program title:-Basic metal work Version -1
Author/Copyright Level -I October 2019
Fig.1.4. a 90° bend
The neutral bending line is sometimes taken as one-third or half the thickness of the
material, applied from the inside of the bend.
The general equation for the length of the neutral bending line at a radius corner for any
regular bend assuming 1/2 of the thickness of the material, applied from the inside bend is
b = fl + tJ2) Where 0 = angle through which stock is bent 180 r = internal radius = 0.01745
(O) (r + t12) t = thickness or diameter of material b length of arc at neutral bending line
If θ= 9O’, then the value of (θΠ)/ 180 = 1.571 and the equation for a 90° bend becomes
b90= 1,571 (r+t /2) (1)
Note that if the work piece is a rod t is replaced by d, diameter of the rod.
Examples 1) find the developed length in mm. of the part shown below.

Solution The part should be redrawn and internal dimensions applied as shown The internal
radius for the given rod with diameter equals 8mm is R = 50 - 8 = 42mm.
The lengths of the linear dimensions are: N, = 100-42 = 58mm & N2 = 150-42 = 108mm. The
length of a at the neutral bending line is calculated using (1) as b 1.571 Fr+t’2) =
1.571(42÷8.2) = 7227mm .
Similar result is also found using arc length formula for different angle bends. In this case for
90 degree bend be D) =14 or [11x2(r+O.5t)J/4 gives the same blank length to the calculated
one. Thus the developed length or the required blank length L is N1 + N2 + a = (58 + 108 +
72.27) mm = 238.27mm.

Page 14 of 67 Federal TVET Agency TVET program title:-Basic metal work Version -1
Author/Copyright Level -I October 2019
2) Calculate the length of the blank required to form the Coat hanger shown below.

Assume that the diameter of the rod is 10mm also explain the procedures how this part is
made in a smith forging shop.

The bend allowance AB = nR (for semi circle)

3.14x 35mm = 10990mm
The bend allowance BC = =54, 95mm
2 .Length of flat ab = 52- (80—2) = 12 mm end length of flat be = 70mm.
Thus the total length of blank L = ab+ cd + AB + BC = 12 + 70 + 109.9 + 54.95 = 264.85 mm
(before bending)
3) Find the developed length to form an eye shown below.

Solution : the length of material required to form the eye is calculated on the mean diameter,
as the neutral axis is the middle line of the metal all the way round Using the blacksmith’s
formula; L of the eye at the neutral line = 3d + 4T where d1 = Inside diameter, T = Thickness
diameter of metal used = (3x60 + 4X8)mm = 212mm.
Therefore, the total developed length is the sum of L of eye and L of the flat which is 1 2mm.
Like example (1) above, approximately the same result is found for the Length of the eye
applying the circumference of neutral line and following the steps it is possible to determine
the blank length.
Bending is not a difficult process; it does not require much skill.

Page 15 of 67 Federal TVET Agency TVET program title:-Basic metal work Version -1
Author/Copyright Level -I October 2019
The stages involved are as follows:
1. Use chalk to mark the length that is to be bent.
2. Hear (pay attention to) the portion to be bent.
3. Place the marked line on an anvil.
4. Using the hammer (select the correct weight), bend the length to the angle required
(Fig.1.5. (a)). If you are forming an eye, continue with the following stages:
5. Turn the work over on the hick and hammer i at the end (Fig.1.5 (b)).
6. Work backwards (Fig.1.5.(c)).
7. Turn it again and curve it round using the hick of the anvil (Fig. (d).

 Never attempt to form the eye directly; bend it at right angles first.

Determine the length of metal to be formed, which is equal to three times the mean diameter.
For example to make a 24 mm external diameter eye from an 8 mm diameter rod, you will
need 3 X (20 + 8) mm 84 mm of material.

Fig.1.5. Bending/forming an eye: (a) first stage bending at right angles; (b) second stage; (C)
third stage; (d) final stage.

Page 16 of 67 Federal TVET Agency TVET program title:-Basic metal work Version -1
Author/Copyright Level -I October 2019
Page 17 of 67 Federal TVET Agency TVET program title:-Basic metal work Version -1
Author/Copyright Level -I October 2019
1.8. Upsetting or jumping up

 This process increasing the cross-section.

 It is a difficult process and requires skills developed over the bars.

 The end to be processed is heated (it must be very hot before it is jumped-up
on the anvil.

 Upsetting involves the following stages:

I. Heat the portion to be jumped up.
2. Bounce the metal on the anvil face.
3. Hold the bar in the vice and hammer the end.

Page 18 of 67 Federal TVET Agency TVET program title:-Basic metal work Version -1
Author/Copyright Level -I October 2019
1.8. Swaging

 Swaging is the process of finishing a round or hexagonal section of bar.

 It is made possible by the use of a pair of swages (Fig.1.6.). The process involves:
1. hearing the metal;
2. placing the metal between the top and bottom swages;
3. striking the top swage while rotating the work.

Fig.2.6. swaging process

1.9. Punching and drifting

 You use punches and drifts to make round or square hole in hot metals. The advantage
of punching and drifting is that they do not remove any metal, unlike drilling, which does.
The metal is left on each side of the hole

 Punching therefore ensure that the grain structure of the metal is not disturbed after
forging. The procedure for punching and drifting is as follows:

Page 19 of 67 Federal TVET Agency TVET program title:-Basic metal work Version -1
Author/Copyright Level -I October 2019
 1. Heat the metal to near welding heat.
2. Punch the hole first on the anvil.

3. Turn the piece above the punch hole and punch through the dark underside of the
piece.
4. True up the punched hole using the drift,

Fig.1.7. Punching and drifting.

Quench the end of the punched after use. to avoid splitting, upset the piece before punching

1.10. Fullering

As mentioned earlier, this process involves the use of fullers in pairs. Before drawing down
fullers is carried out to produce shoulder. Fullers are not used to cut and therefore they only
change the direction of the grains of the metal (Fig.2.8.).
In fullering:
1. Mark the length to be drawn down.
2. Hear the metal.
3. Notch or neck the point with arc drawing down is I start (Fig.2.8 (a)).
4. Finish off the rough surface using the flatter (see below).

Fi
g.1.9. Fullering

Page 20 of 67 Federal TVET Agency TVET program title:-Basic metal work Version -1
Author/Copyright Level -I October 2019
 1.11. Flattening
You use the flatter with the sledge hammer to flatten filtered piece (Fig.1.9.).
Flattening enables you to finish off an undulating surface.
To flatten:
1. Hold the flatter on the surface.
2. Strike the end of the Hatter with the sledgehammer.
3. Move the Hatter to all areas and repeat step 2.

Fig.1.10. Flattening

Page 21 of 67 Federal TVET Agency TVET program title:-Basic metal work Version -1
Author/Copyright Level -I October 2019
 Information Sheet-2 Selecting Hand tools and formers

2. Use hand tools and formers

 Occupations in forging
The main kinds of workers in the forging shop includes

 Heaters: -workers who heat the metal to the correct temperature.

 Blacksmiths: -worker who forge by hand.

 Hammer smith:- uses power hammers equipped with unshaped dies to

hammer metal in to shape.

 Hammer operators: -use forging machines in which the heated metal is

poured into shape between accurately machined dies called closed dies.

 Inspectors- check the forgings.

 Finishers: -remove burrs, chip imperfections from the finished forgings.

 Ornamental-iron worker:- makes and installs wrought-metal decorations for

buildings and homes, This worker heats metal and shapes into artistic
designs

Page 22 of 67 Federal TVET Agency TVET program title:-Basic metal work Version -1
Author/Copyright Level -I October 2019
 Fig.2.1

Page 23 of 67 Federal TVET Agency TVET program title:-Basic metal work Version -1
Author/Copyright Level -I October 2019
Page 24 of 67 Federal TVET Agency TVET program title:-Basic metal work Version -1
Author/Copyright Level -I October 2019
Page 25 of 67 Federal TVET Agency TVET program title:-Basic metal work Version -1
Author/Copyright Level -I October 2019
Page 26 of 67 Federal TVET Agency TVET program title:-Basic metal work Version -1
Author/Copyright Level -I October 2019
Page 27 of 67 Federal TVET Agency TVET program title:-Basic metal work Version -1
Author/Copyright Level -I October 2019
Page 28 of 67 Federal TVET Agency TVET program title:-Basic metal work Version -1
Author/Copyright Level -I October 2019
Page 29 of 67 Federal TVET Agency TVET program title:-Basic metal work Version -1
Author/Copyright Level -I October 2019
Page 30 of 67 Federal TVET Agency TVET program title:-Basic metal work Version -1
Author/Copyright Level -I October 2019
2.1. Using hand tools and formers correctly and in accordance with safety procedures.

There are five basic rules that apply to all hand tools used either hand or power.
 Keep all tools in good working order
 Use the tool only for what it is designed to do
 Examine the tool for damage before each use
 Always follow the manufacturer’s instructions when operating any tool
 Always wear the appropriate PPE when operating any tool.
 SAFETY RULES for SPECIFIC Hand Tools
Hammers
 Use a claw hammer for pulling nails
 Do not strike a hardened steel surface with a claw hammer
 Do not strike one hammer against another hammer
 Do not use a hammer as a wedge or pry-bar

Fig.2.2
CHISELS

 Use only chisels that are sharp

 Do not use chisels with a mushroom head
 Use only hammers that are designed for use with chisels

Page 31 of 67 Federal TVET Agency TVET program title:-Basic metal work Version -1
Author/Copyright Level -I October 2019
 Fig.2.3

Swage block
It is usually a block of cast steel or cast iron carrying a number of slots of different shapes
and sizes along its four side faces and through holes from its top face to bottom face.
This is used as a support in punching holes and forming different shapes. The job to be
given a desired shape is kept on a similar shaped slot, which acts as a bottom swage, and
then the top swage is applied on the other side of the job.
The holes in the top and bottom face are used in punching. Their use prevents the punch
from spoiling by striking against a hard surface after the hole has been punched.

Fig.2.4
Tongs
They are used to hold the jobs in position and turning over during forging operation. they are
made of mild steel.
Tongs are usually made in two pieces, riveted together to form a hinge. Smaller length on
one side of the hinge carries the holding jaws, which are made in different shapes and sizes
to suit the corresponding shapes and sizes of the jobs, and the longer portions on the other
side of the hinge form the arms which are held in hand by the smith.
Over all sizes of the tongs vary according to the size and shape of the job to be held, but the
commonly used lengths of the tongs in hand forging vary from 400 mm to 600 mm with the
jaws’ opening ranging from 6mm to 55 mm.

Page 32 of 67 Federal TVET Agency TVET program title:-Basic metal work Version -1
Author/Copyright Level -I October 2019
Tongs are usually named after the inside shapes of the jaws.
Flat tongs are used for gripping thin section and small flat pieces.
Round hollow tongs, with curved surface inside, are used for holding round work.
Hollow tongs with square jaws are used to hold square or hexagonal work. Pick up tongs
have their jaws so shaped that even small sections can be easily picked up. They are not
used for holding the work.

Fig.2.5
 Punches
Punches are tapered tools made in various shapes and sizes. They are used for producing
holes in red hot jobs. A larger tapered punch is called a drift.
The job is placed on the anvil and the punch is hammered through it up to about half its
depth. In is then turned over and the punch made to pass through it. Completion of this
operation in two stages prevents the job from splitting and full to bursting.

Fig.2.6
 Flatters
These are also known as smoothers. They are made of high carbon steel and consist of a
square body, fitted with a handle, and a flat square bottom. They are used for leveling and
finishing a flat surface after drawing out or any other forging operation.

Page 33 of 67 Federal TVET Agency TVET program title:-Basic metal work Version -1
Author/Copyright Level -I October 2019
Fig.2.7
 Anvil
 To carry out the forging operations successfully, a proper supporting device is needed
which should be capable of withstanding heavy blows rendered to the job.
 An anvil stands as the most appropriate choice for this purpose.
Its body is generally made of cast steel, wrought iron or mild steel provided with a
hardened top, about 20 to 25 mm thick.
This hardened plate is welded to the body on the top.

 The horn or beak is used in bending the metal or forming curved shapes.
 The flat step provided, between the top and the horn, is used to support jobs during
cutting and is known as chipping block.
 The flat projecting piece at the back of the anvil is known as tail.
 It carries a square hole to accommodate the square shank of the bottom part of
various hand tools like swages, fuller. It is called a hard die hole.
 The circular hole provided near the hard die hole is known as pitcher hole.

 The commonly used size of an anvil weighs approximately 50-150 kg although it is

manufactured in various sizes.

 The top face of the anvil should stand at about 0.75 m from the floor.

Fig.2.8

Page 34 of 67 Federal TVET Agency TVET program title:-Basic metal work Version -1
Author/Copyright Level -I October 2019
  Info 3 Forging temperatures and heat specifications are applied to for various materials
requirement

 Info 4 Work plan is drafted according to specifications

Self-Check -1 Written Test

Directions: Answer all the questions listed below. Use the Answer sheet provided in the
next page

PART ONE: - GIVE the Short answer and blank space (each has 2 point)

1. what is the advantage and disadvantage of forging

2. List down the types of forging
3. _____is one of the oldest metal working operations known, used in making parts of
widely varying sizes and shapes from a variety of metals.

PART TWO: – True /false (each have 2point)

1. In Hand forging process the forgings are made with the help of repeated blows in an
open die.
2. The necessary tools and equipment’s used for hand forging is Flatters, set hammers,
ball peen hammer, welding machine.
3. The raw material for forging is usually a bar, billet or sheet metal.
4. Forging is the plastic working of metal by means of localized compressive forces.

Note: Satisfactory rating - 30 points Unsatisfactory - below 15 points

You can ask you trainer for the copy of the correct answers.

Page 35 of 67 Federal TVET Agency TVET program title:-Basic metal work Version -1
Author/Copyright Level -I October 2019
Answer Sheet Score = ___________

Rating: ____________
[Link] One

1.

1. Usually have better mechanical properties, especially if the fiber flow lines are directed.

2. Can be held to within fairly close dimensional tolerances

3. A wide range of forgeable metals is available

4. Forgings are readily welded & incorporated in welded structures.

2.

1. Many intricate and cored shapes possible by casting processes can’t be forged

2. Usually forgings cost more than castings

3. Closed impression dies for forgings normally cost more than patterns.

4. Permanent molds, or die equipment needed for casting processes

5. High tool cost and high tool maintenance

6. Limitations in size and shape

7. High tool cost and high tool maintenance and Limitations in size and shape
3. Forging

1. True
2. False
3. False
4. True
Name: _________________________ Date: _______________

Page 36 of 67 Federal TVET Agency TVET program title:-Basic metal work Version -1
Author/Copyright Level -I October 2019
LO2: Perform hand forging techniques

Information Sheet- 1 Setting up and operating Heating equipment

2. Perform Hand forging techniques.

2.1 Setting up heating equipment

 Heating Procedure of Metal Setting for fire

 Clean out the old fire from the forge hearth and remove the ash
 .Put some wood shaving over the tubers and light.
 Turn on a little air using litters by hand or power blower
to get the fire started
 Keep a forging fire neutral throughout the heating of
metal.

2.2. Operating Heating equipment.

 Heating Devices (Hearths and Furnaces)

 .The heating of metal is done either in a smith’s hearth or in a furnace.

 .The hearths (commonly known as forges) are used for heating metals for hand forging.

 .It is a very old method of heating still it is used.

 .The furnaces are used for heating metals for heavy forging

Page 37 of 67 Federal TVET Agency TVET program title:-Basic metal work Version -1
Author/Copyright Level -I October 2019
1. Hearths: - the hearths may be classified as open or closed hearths, the blacksmith forges
may have one or two hearths which are called single hearth or double hearth.
Respectively.

 A common form of the hearth

 Single hearth open type consists of a shallow dish or tray made of heavy gauge mild
steel or cast iron sheets. Its size varies from 1.5 m to 2.5m square and 0.8 m to 1.2 m
deep. Look at Fig.2.10 below.

 It is provided with a lining of fire clay or other refractory material to withstand the
excessive heat produced due so the combustion of fuel.

Fig.2.10.

 The fuel used in a hearth may be

 coke,

 Coal or charcoal.

 The smoke and gases produced due to the burning of fuel is escaped through hood and
chimney.

Page 38 of 67 Federal TVET Agency TVET program title:-Basic metal work Version -1
Author/Copyright Level -I October 2019
 Water tank is provided for the purpose of quenching the work.
The closed type hearths are employed in mass production for heating small parts.

The hearths may be made of bricks especially for heavy work.

2. Furnaces: - The furnaces of refractory type are mostly used for heating large work to be
forged under power hammers.

 Since the work, in the furnaces, is heated by the flames produced from the
combustion of fuel, therefore these furnaces may be called as flame furnaces.

 The gas and oil mostly used as fuels as these are economical and easily controlled.

 The work does not come in direct contact with the fuel.

 The following are the various types of furnaces used for heating steel.

a).Box or box type furnaces:- These are widely used in forging shops for heating small and
medium size work; these furnaces are usually made of steel frame lined with insulating and
refractory bricks.

b) .Continuous type furnaces: - These furnaces are provided with mechanical pusher and
are tad for mass production of articles. In these furnaces, the pieces of steel are charged at
one end and pushed to the furnace for heating at correct temperature.

Page 39 of 67 Federal TVET Agency TVET program title:-Basic metal work Version -1
Author/Copyright Level -I October 2019
c) Slot type furnaces: - These furnaces are commonly used for heating bars at one
end for forging or other forging operation, in these furnaces, a slot is provided at the front
through which the bar is inserted for heating

d).Rotary hearth furnaces: - These furnaces are sometimes used for heating large number
of pieces steel for forging. In these furnaces, the speed of rotation is adjusted in such a way
that the ink is heated to the required temperature after one or two revolutions.

e).
High frequency induction furnaces:-these furnaces are quite popular with the availability
(cheap electric power).

Page 40 of 67 Federal TVET Agency TVET program title:-Basic metal work Version -1
Author/Copyright Level -I October 2019
The work produced by induction heating is free from oxide scale, have uniform temperature
and takes less time,
f) Resistance furnaces:- These furnaces are faster than induction furnaces are often
automated in these furnaces; the work is connected to the circuit of a step down transformer.
The simple fixtures made to hold the work of different shapes and sizes.
F). Blowers: - the supply of air at proper pressure is always necessary for the combustion of
fuel in the hearth or furnace

 Open Fire

1. Open fire:-The open fire (also called loose fire), as shown in Fig. 1(a), is used for ‘all
general work. It is made in the hollow space with coke left from the last fire, covered
with green coal. At the fire burns away. Coke from the top and sides is thrust into the
centre and its place is taken by green coal from the supply maintained on from plate
of the forge. the ash and clinkers clean at regular intervals of time.

2.3. Controlling Heat to specified areas

 Heat during forging is controlled by the color of the metals.

 Heating the metal
 Never put the metal from the top with one end at the bottom of the fire. This heats the
metal unevenly.
 Always place or put the metal in the center in a horizontal position.
 Remove the metal from the fire at intervals to see how hot it is.
 Heat the metal to its proper color and temperature.
 Poorly heated metal will be difficult to forge and is liable to cracks.
 The temperature of steel for forging is determined by temperature color.
Temper Color Temperature (0C) Temper Color Temperature (0C)
Brown 500 Orange Yellow 1000
Dark Purple 550 Straw Yellow 1100
Dark Red 650 Very Light Yellow 1200

Page 41 of 67 Federal TVET Agency TVET program title:-Basic metal work Version -1
Author/Copyright Level -I October 2019
Cheery Red 700 White 1300

Light Cheery Red 800 Bright White 1400

Dark Orange 900

 Allowance for Forged material

Shrinkage allowance

Length or width, mm Commercial. or - mm Close + or - mm

Up to 25 008 0.05
26 to 50 0.15 0.06
51 to 75 0.23 0.13
76 to 100 0.30 0.15
101 to 125 0.38 0.20
126 to 150 0.45 0.23
each additional 25 add 0.075 0.038
For example 400 1.200 0.830

 Shrinkage allowance
The forgings arc generally made at a temperature of 1150 t0 1300 C. At this temperature,
the material gets expanded and when it is cooled to the atmospheric temperature, its
dimension would be reduced. it is very difficult to control the temperature at which forging
process would be complete, therefore to precisely control the dimensions. Hence a
shrinkage allowance is added on all the linear dimensions given in Table 19.4.

Page 42 of 67 Federal TVET Agency TVET program title:-Basic metal work Version -1
Author/Copyright Level -I October 2019
 Die wear allowance
The die wear allowance it added to account for the gradual wear of the die which takes
place with the use of the die. The suggested values are presented in Table following
table:

 Finish allowance
Machining allowance is to be provided on the various forged surfaces which need to he
further

2.4. Applying appropriate forging technique

 Defect in Forgings
The following are some of the reasons for forging defects:
(I) .Faulty original metal,
(II). Incorrect die design.

Page 43 of 67 Federal TVET Agency TVET program title:-Basic metal work Version -1
Author/Copyright Level -I October 2019
 (III). Improper heating, and
(IV) .improper forging operation.
 Info 2 Appropriate forging techniques are applied and carried out in accordance with safety
procedures

 Info 3 Allowance is made for materials shrinkage and oxidization

Self-Check -2 Written Test

Directions: Answer all the questions listed below. Use the Answer sheet provided in the
next page:

 PART ONE – CHOOSE

1. ------ process involves the use of fullers in pairs, before drawing down fullers is
carried out to produce shoulder.

A. heating B. punching C. fuller D. smith E. none

2. -------------- is the process of finishing a round or hexagonal section of bar.

A. bending B. Swage C. upsetting D. punching

3. ________process increasing the cross-section of a at the expense of its length.

A. upsetting B. Punching C. bending D. Swage

4. The forging operation of “upsetting” is…….

(a) Reverse of drawing down process (b) it is a bending operation
(c) It is a drifting operation (d) none of these.
 Part III short answer Matching
Column A Column B

1. ___Internal crack A. reducing cross sectional area

2. ___Punching B. producing a bar with a smaller diameter

Page 44 of 67 Federal TVET Agency TVET program title:-Basic metal work Version -1
Author/Copyright Level -I October 2019
 3. ___Fullering C. due to secondary tensile stress
4. ___Swaging D. producing hole
5. ___Drawing E. increasing diameter &cross sectional area
6. ___Upsetting F. reducing cross section area &increasing in length.

[Link] ONE (self-check-2)

1. C 1. C 5.F

2. B 2. D 6.E

3. A 3. A

4. A 4. B

Note: Satisfactory rating - 30 points Unsatisfactory - below 15 points

Name: _________________________ Date: _______________

Page 45 of 67 Federal TVET Agency TVET program title:-Basic metal work Version -1
Author/Copyright Level -I October 2019
LO3: Quality assure work
Information Sheet-3 Following Occupational Health and Safety (OHS) measures and
procedures

3. SAFETY PRECAUTIONS
 Some safety precautions generally followed while working in forging shop are given as
under.
1. Always avoid the use of damaged hammers.
2. Never strike a hardened surface with a hardened tool.
3. No person should be allowed to stand in line with the flying objects.
4. Always use the proper tongs according to the type of work.
5. The anvil should always be free from moisture and grease while in use.
6. Always wear proper clothes, foot-wears and goggles.
7. The handle of the hammer should always be tightly fitted in the head of the hammer.
8. Always put out the fire in the forge before leaving the forge shop.
9. Always keep the working space clean.
10. Proper safety guards should be provided on all revolving parts.
11. Head of the chisel should be free from burrs and should never be allowed to spread.
12. During machine forging, always observe the safety rules prescribed for each machine.
13. One must have the thorough knowledge of the working of the forging machine before
operating it.
 DEFECTS IN FORGED PARTS
Defects commonly found in forged parts that have been subjected to plastic deformation are
as follows.

 Defects resulting from the melting practice such as dirt, slag and blow holes.
 Ingot defects such as pikes, cracks scabs, poor surface and segregation.
 Defect due to faulty forging design.
 Defects of mismatched forging because of improper placement of the metal in the die.
 Defects due to faulty design drop forging die.
 Defects resulting from improper forging such as seams cracks laps. etc.

Page 46 of 67 Federal TVET Agency TVET program title:-Basic metal work Version -1
Author/Copyright Level -I October 2019
  Defects resulting from improper heating and cooling of the forging part such as burnt
metal and decarburized steel.

Information Sheet-4 Controlling heat to specified areas

4. HEAT TREATMENT OF FORGING

Heat treatment is carried out for releasing the internal stresses arising in the metal during
Forging and cooling of work piece. It is used for equalizing the granular structure of the
forged Metal and improving the various mechanical properties.
The following are the purposes of heat treatment:
i. To remove internal stresses set-up during forging and cooling.
ii. To normalize the internal structure of the metal.
iii. To improve mach inability.
iv. To improve mechanical properties, strength and hardness.
Generally forged parts are annealed, Normalized and tempered to obtain the desired results
4.1. Annealing of forged metals

One of the most important processes of heat treatment of steel is employed for the following
purpose:

1. To soften the steel so that it may be more easily machined or cold worked
2. To refine the grain size & structure to improve mechanical properties like strength &
ductility
3. To relieve internal stress which may have been caused by hot or cold working or by
unequal contraction in casting
4. To alter electrical, magnetic or other physical properties
5. To remove gases trapped in the metal during initial casting
4.2. Normalizing of forged metals
Normalizing is done for the following purpose

1. To refine the grain structure of forged metals to improve machine ability, tensile
strength and structure of weld.
2. To remove strains caused by cold working process like hammering, rolling, bending
etc, this makes the metal brittle and reliable.

Page 47 of 67 Federal TVET Agency TVET program title:-Basic metal work Version -1
Author/Copyright Level -I October 2019
 3. To remove dislocations caused in the internal structure of forged metal due to hot
working.
4. To remove certain mechanical and electrical properties.
 The process of normalizing consists of heating 300c-500c above its critical
temperature.
4.3. Hardening of forged metals
It is defined as the heat treating process in which the forged metals are to 20 0c above
the transformation range soaking at this temperature for considerable period to ensure
through penetration of the temperature inside the component, followed by continuous
cooling to room temperature by quenching in water oil or brine solution.

4.4. Tempering forged metals

Forged metals hardened by rapid quenching are very and brittle. It also contains internal
stresses which are severe and unequally distributed to cause cracks or even rapture or
hardened steel (the tempering is known as drawing) is done for the following reasons:

1. To reduce brittleness of the hardened forged metals and to increased ductility.

2. To remove the internal stresses caused by rapid cooling
3. To make forged metals to resist shock and fatigue

 Operate heating equipment

Heating Devices (hearth and Furnaces)

The heating of metal is done either in a smith’s hearth or in a furnace. The hearths
(commonly known as forges) are used for heating metals for hand forging. It is a very old
method of heating still it is used. The furnaces are used for heating metals for heavy forging.

1. Hearths: - the hearths may be classified as open or closed hearths, the blacksmith forges
may have one or two hearths which are called single hearth or double hearth respectively.

A common form of the hearth, as shown in Fig (a), is a single hearth open type forge. Its size
varies from 1.5 m to 2.5m square and 0.8 m to 1.2 m deep. It is provided with a lining of fire
clay or other refractory material to withstand the excessive heat produced due so the
combustion of fuel.

Page 48 of 67 Federal TVET Agency TVET program title:-Basic metal work Version -1
Author/Copyright Level -I October 2019
Fig 4.1. Heating Devices (hearth)

The fuel used in a hearth may he coke, coal or charcoal. For general work, low sulphur is
used. There is an inlet for blowing air either through the back or bottom. The air is generally
applied through a motorize fan blower. The motorized fan is generally fitted with a series-
wound variable speed motor.

Heating controls allow you to easily regulate the temperature of your home. The controls
automatically turn the heating on and off based on settings input by the user, to ensure
maximum comfort. ... The latest technology allows you to automatically control your heating
to work around your daily schedule.
Temperature is the most important one because it provides a critical condition for
combustion, chemical reaction, fermentation, drying, calcinations, distillation, concentration,
extrusion, crystallization, and air conditioning. Poor temperature control can cause major
safety, quality, and productivity problems.

If your temperature is above 250°F, close down the vents to reduce the amount of oxygen in
order to reduce the temperature. If your temperature dips below 225°F, open up the vents
fully to allow more oxygen in to increase the temperature. Learn more about temperature
control.
 No-Cost Ways to Improve Air Conditioning Efficiency

1. Clean around outdoor condenser unit

2. Vacuum indoor vents and keep vents unblocked.
3. Increase your thermostat by a few degrees.

Page 49 of 67 Federal TVET Agency TVET program title:-Basic metal work Version -1
Author/Copyright Level -I October 2019
 4. Keep lamps and other heat producing appliances away from your thermostat.
5. Keep curtains and blinds closed in the heat of the day.
6. Clear your drain line

 MATERIALS USED IN FORGING:

Mostly in forging, Ferrous & Non-Ferrous metals are used in manufacturing purpose.

 Ferrous metals: these contain iron as a main constituent, these are stronger.
Some of them are low and medium carbon steels, alloy steels, stainless steels, titanium,
die-steels.
FERROUS METAL FORGING [Link] ◦C

1. Low carbon steel 1250◦C

2. Medium carbon steel 850-1100◦C

3. Stainless steel 1200◦C

 Non-Ferrous metals:
Non-ferrous metals do not contain iron as the main constituent. Generally they are weaker
than ferrous metals but have other important properties such as corrosion resistance, high
electrical and thermal conductivity, good formability and special electrical & magnetic
properties the chief non-ferrous metals used in the industrial purpose are copper, aluminum,
zinc, lead, tin, magnesium and their alloys.

 NON-FERROUS METALS FORGING TEMP IN ◦C

1. Brass 650-800◦C

2. Bronze 825-900◦C

3. Aluminum alloys 350-450◦C

4. Copper 900◦C

FORGING TEMPERATURES

• Forging temperature is a temperature at which a metal becomes soft like clay or its shape
can be changed by applying a relatively small force without creating cracks in metal.

Page 50 of 67 Federal TVET Agency TVET program title:-Basic metal work Version -1
Author/Copyright Level -I October 2019
• Note: - Temperatures for alloys (combination of metals) will lie between the temperatures
specified for the metals utilized.

When heating a piece of steel on a forge the blacksmith must always watch the flame of the
fuel. Metal is best heated a bright slightly smoking flame, because such a flame excludes all
possibility of overheating the metal. the difference between the initial and final forging
temperature is called the forging temperature interval.

There are three temperature ranges-cold, warm, and hot working:

Cold working Warm working hot working

TA 0.3Tm 0.5Tm 0.75 Tm

TA is the ambient (room) temperature, and Tm is the work metal melting temperature

 Cold working is metal forming performed at room temperature.

 Advantages: better accuracy, better surface finish, high strength and hardness of the
part, no heating is required.
 Disadvantages: higher forces and power, limitations to the amount of forming,
additional annealing for some material is required, and some material are not capable
of cold working.
 Warm working is metal forming at temperatures above the room temperature but bellow
the recrystallization one.
 Advantages: lower forces and power, more complex part shapes, no annealing is
required.
 Disadvantages: some investment in furnaces is needed.

 Hot working involves deformation of preheated material at temperatures above the

Re-crystallization temperature.

Page 51 of 67 Federal TVET Agency TVET program title:-Basic metal work Version -1
Author/Copyright Level -I October 2019
  Advantages: big amount of forming is possible, lower forces and power is required,
forming of materials with low ductility, no work hardening and therefore, no additional
annealing is required.
 Disadvantages: lower accuracy and surface finish, higher production cost, and shorter
tool life.

Chart:- [Link] forging temperature

 Color of Metals in Forging

The temperature of steel for hand forging is generally determined by temperature color in
the following four general ranges.
 Red heat (about 470 C) is used for making easy bends in mild steel and for forging
the HCS as in Loop making.
 Cheery- Red heat (about 790 °C) is used for simple forging operation such as for hot
cutting and light punching of mild steel and HCS.
Note. HCS must not be raised above cherry red. They will loosen their especial
property.
 Bright cherry red heat (about 1100 All principal forging operations are carried out at
this heat on mild steels, Drawing down, upsetting, fullering, punching, etc are
performed at this temperature.
White heat (welding heat, about 1260-1400 °c). As the metal approaches white heat it
becomes plastic.

Page 52 of 67 Federal TVET Agency TVET program title:-Basic metal work Version -1
Author/Copyright Level -I October 2019
4.5. CONTROL OF HEATING DEVICES

For good control of heating devices such as hearth or forging furnace, the following points
are should always be considered.

1. The nozzle pointing into the centre of the hearth is called the tuyre and is used to direct a
stream of air into the burning coke. The air is supplied by centrifugal blower.

2. As the hottest part of the fire is close to the tuyre opening, therefore, the tuyre is provided
with a water jacket to prevent it from burning away.

3. The hood provided at the top of hearth collects smoke, fumes etc., and directs them away
from the workplace through the chimney in form of exhaust.

4. The fuel for the fire may be either black-smiting coal or coke. To light the fire, either use
paper and sticks or preferably a gas poker.

5. Impurities will collect as clinker and must be removed from the bottom of the fire when the
fire cools.

6. The blowers are used to control the air supply using forced draught. Regulators control the
draught and the temperature of the fire.

7. Blower delivers to forge adequate supply of air at proper pressure which is very necessary
for the combustion of fuel.

8. A centrifugal blower driven by an electric motor is an efficient means of air supply

in forging hearth.

9. Fire tools such as rake, poker and slice are generally used to control or manage the fire
and theses tools are kept nearby the side of the hearth. Rake is used to take heated work
piece out of the fire. Poker is a steel rod which is used to poke (stir) fire in the hearth.

10. The place of the metal to be heated should be placed just above the compact centre of a
sufficiently large fire with additional fuel above to reduce the heat loss and atmospheric
oxidation

Page 53 of 67 Federal TVET Agency TVET program title:-Basic metal work Version -1
Author/Copyright Level -I October 2019
 Making preventive maintenance
Maintenance is a broad definition concerned with controlling the condition of equipment.

The trainees should detect the overhaul preventive maintenance (PM) action of Forge hand
tools & hammers, formers & heating equipment.

This moderate approach begins with an attempt to plan on preventive maintenance of a

forge work.

1. Cleaning, repairing hand tools, formers, heating equipment

2. Select preventive maintenance task
3. Choose preventive maintenance interval with normal life span
4. Determine normal life span before defect
5. Prevent hand tools, formers, hammers & forging machines from deterioration
6. Lubricating forging machine
7. Checking daily surveillance of forging machine

Page 54 of 67 Federal TVET Agency TVET program title:-Basic metal work Version -1
Author/Copyright Level -I October 2019
 Self-Check -3 Written Test

Directions: Answer all the questions listed below. Use the Answer sheet provided in the
next page:

 PART ONE – CHOOSE

1. Advantage of cold working is

(a) Better dimensional accuracy (b) better surface finish

(c) Higher strength (d) all of these.
2. Typical hot working temperature range for steel is

(a) 650–1050°C (b) 650–723°C

(c) 500–910°C (d) none of these.
3. The forging operation of “upsetting” is

(a) Reverse of drawing down process (b) it is a bending operation

(c) It is a drifting operation (d) none of these.

[Link] ONE (self-check-3)

1. D 3. A

2. A

Page 55 of 67 Federal TVET Agency TVET program title:-Basic metal work Version -1
Author/Copyright Level -I October 2019
Operation sheet-1
OPERATION TITLE:-Upsetting or jumping up

PURPOSE: This process increasing the cross-section of a at the expense of its length
CONDITIONS OR SITUATIONS FOR THE OPERATIONS:

EQUIPMENT TOOLS AND MATERIALS: - Tong, Forge, Round bar Charcoal, PPE
PROCEDURE:
1. Heat the portion to be jumped up.
2. Bounce the metal on the lower die.
3. Hold the bar with tong and hammer the end.
PRECAUTION: use PPE and tongs
QUALITY CRITERIA: Dimensional accuracy and Surface finish

OPERATIONTITLE:-Drawing down
PURPOSE: This process makes the metal thinner, by reducing its cross-section. Metal to be
forged is first hammered on the back of an die. The process can produce tapers that arc,
Hat, circular, or square. Fig. shows the steps to follow in drawing down a circular taper:
EQUIPMENT TOOLS AND MATERIALS:- Tong ,Hearth ,Round bar Charcoal, PPE, drop
Hammer
PROCEDURE:
I. Hammer four sides to produce a short square (Fig.a)
2. Lengthen the square taper (Fig.b)).
3. Hammer the corners of the long square in step 2 to produce an octagonal shape (Fig. (c)).

4. Continue round all the corners in step 3 to obtain a circular end (Fig. (d)). if the taper is fat
or square go through either the first two or three stages above.

Page 56 of 67 Federal TVET Agency TVET program title:-Basic metal work Version -1
Author/Copyright Level -I October 2019
  Avoid piping (hollow ends) when drawing down a taper.

Fig.1.1. Stages in drawing down: a) first stage -short square; b) second stage- long square;
(C) Third stage-octagonal shape; (dl final stage-round shape.
PRECAUTION: use PPE and tongs
QUALITY CRITERIA: Dimensional accuracy and Surface finish. Roundness.

OPERATIONTITLE: - Flattening

EQUIPMENT TOOLS AND MATERIALS: - Tong, Hearth, Round bar Charcoal, PPE, drop
Hammer
PROCEDURE: You use the flatter with the sledge hammer to flatten filtered piece Flattening
enables you to finish off an undulating surface.
To flatten:
1. Hold the hot metal on lower die.
2. Strike the work piece with the drop hammer
3. Move work pieces them to all areas and repeat step 2.
PRECAUTION: use PPE and tongs
QUALITY CRITERIA: Dimensional accuracy and Surface finish. Roundness

Page 57 of 67 Federal TVET Agency TVET program title:-Basic metal work Version -1
Author/Copyright Level -I October 2019
Operation sheet-2
OPERATION TITLE:- S-Hook

PURPOSE: This process increasing the cross-section of a at the expense of its length
CONDITIONS OR SITUATIONS FOR THE OPERATIONS:

EQUIPMENT TOOLS AND MATERIALS: - Smith’s forge, Anvil, 500gm and I kg ball-peen hammers,
Flatters, Swage block, Half round tongs, Pick-up tongs, Cold chisel.
PROCEDURE:
Aim: To make an S-hook from a given round rod, by following hand forging operation.
Tools required:
Sequence of operations:
1. One end of the bar is heated to red hot condition in the smith’s forge for the required
length.
2. Using the pick-up tongs; the rod is taken from the forge, and holding it with the half round
tongs, the heated end is forged into a tapered pointed end.
3. The length of the rod requires for S-hook is estimated and the excess portion is cut-off,
using a cold chisel.
4. One half of the rod towards the pointed end is heated in the forge to red hot condition and
then bent into circular shape as shown.
5. The other end of the rod is then heated and forged into a tapered pointed end.
6. The straight portion of the rod is finally heated and bent into circular shape as required.
7. Using the flatter, the S-hook made as above, is kept on the anvil and flattened so that, the
shape of the hook is proper.
S- HOOK
NOTE: In-between the above stage, the bar is heated in the smith’s forge, to facilitate forging
operations.
Result:
The S-hook is thus made from the given round rod; by following the stages mentioned
above.
Precautions:
1. Hold the job carefully while heating and hammering

Page 58 of 67 Federal TVET Agency TVET program title:-Basic metal work Version -1
Author/Copyright Level -I October 2019
2. Job must be held parallel to the face of the anvil.
3. Wear steel-toed shoes.
4. Wear face shield when hammering the hot metal
5. Use correct size and type of tongs to fit the work.
6. Use PPE and tongs
QUALITY CRITERIA: Dimensional accuracy and Surface finish S-hook.

Page 59 of 67 Federal TVET Agency TVET program title:-Basic metal work Version -1
Author/Copyright Level -I October 2019
Operation sheet-3
OPERATION TITLE:- Square Rod

PURPOSE: This process increasing the cross-section of a at the expense of its length
CONDITIONS OR SITUATIONS FOR THE OPERATIONS:

EQUIPMENT TOOLS AND MATERIALS: - Smith’s forge, Anvil, 500gm and I kg ball-peen hammers,
Flatters, Swage block, Half round tongs, Pick-up tongs, Cold chisel.
Aim: To make a Square rod from a given round rod, by following hand forging operation.
Sequence of operations:
1. Take the raw material from stock i.e., mild steel 10 mm round shaped, cut the length of 50
mm.
2. Handle specimen with round tong and heat in blacksmith’s forge up to the part appears as
red cherry color code.
3. The required piece heated up to it gets the recrystalization temperature.
4. The part is taken out from the forge and blow with sledge hammer for obtaining the square
shape on all edges.
5. The hammering is done on the anvil.
6. The above mentioned all steps are done, after the specimen bent in required shape.
7. Check the dimensions after cooling the job by quenching process.
NOTE: In-between the above stage, the bar is heated in the smith’s forge, to facilitate forging
operations.
Result:
The square rod is thus made from the given round rod.
Precautions:
1. Hold the job carefully while heating and hammering
2. Job must be held parallel to the face of the anvil.
3. Wear steel-toed shoes.
4. Wear face shield when hammering the hot metal
5. Use correct size and type of tongs to fit the work.

Page 60 of 67 Federal TVET Agency TVET program title:-Basic metal work Version -1
Author/Copyright Level -I October 2019
QUALITY CRITERIA: Dimensional accuracy and Surface finish. Square ness.

Page 61 of 67 Federal TVET Agency TVET program title:-Basic metal work Version -1
Author/Copyright Level -I October 2019
 LAP Test Practical Demonstrations

Name: _____________________________ Date: ________________

Time started: ________________________ Time finished: ________________
Instructions: Given necessary templates, tools and materials you are required to perform
the following tasks within --- hour.

Task 1. Drawing down

Page 62 of 67 Federal TVET Agency TVET program title:-Basic metal work Version -1
Author/Copyright Level -I October 2019
 LAP Test Practical Demonstrations

Name: _____________________________ Date: ________________

Time started: ________________________ Time finished: ________________
Instructions: Given necessary templates, tools and materials you are required to perform
the following tasks within --- hour.

Task 2. S-Hook

Page 63 of 67 Federal TVET Agency TVET program title:-Basic metal work Version -1
Author/Copyright Level -I October 2019
 LAP Test Practical Demonstrations

Name: _____________________________ Date: ________________

Time started: ________________________ Time finished: ________________
Instructions: Given necessary templates, tools and materials you are required to perform
the following tasks within --- hour.

Task 3. Square Rod

Page 64 of 67 Federal TVET Agency TVET program title:-Basic metal work Version -1
Author/Copyright Level -I October 2019
 List of reference materials

[Link] of metal manufacturing Processes’. Beddoes and [Link]

corletonuniversety,Cabada
[Link] to Basic manufacturing processes and work shopTechnology,
Rajender Singh.
[Link]. set .[Link]

Page 65 of 67 Federal TVET Agency TVET program title:-Basic metal work Version -1
Author/Copyright Level -I October 2019
 Acknowledgement

The Federal TVET Agency (FTA) wishes to extend thanks and appreciation to the
representatives of TVET teachers; facilitators form the regional TVET Bureaus and
Agencies, Federal TVET Agencies who donated their time and expertise to the
development of this Model Learning Guide/TTLM/ for the TVET Program of Basic
Metal Works Level-1

The trainers who developed this TTLM

No Name of trainer Qualification Region E-mail

1 TEFERA DEMISSIE A-Level SNNPR teferad123@gmail.
com
2 MULUKEN YENET B-Level AMHARA mulukeynet@gmail.
com
3 KABTAMU SHEWANGIZAW A-Level OROMIA Kabtamushewaangi
zaw@[Link]
4 YOHANNIS HAILE B-Level B.G.R
5 AHMED HUSSEN B-Level SOMALI abdirashidhusen@
[Link]
6 AYSHA SHIBESHI B-Level AFAR yasinmohammed45
9@[Link]
7 TEKALIGN BEKELE B-Level SNNPR
8 BOKA TEREFE A-Level OROMIA bokaterefe@yahoo.
com

This model TTLM was developed on September 04/01/2012 E.C at ADAMA

Page 66 of 66 Federal TVET Agency TVET program title:-Basic metal work Version -1
Author/Copyright Level -I October 2019