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INTRODUCTION
Forging is the process by which metal is heated and is shaped by plastic deformation by
suitably applying compressive force. Usually the compressive force is in the form of
hammer blows using a power hammer or a press.
1. Impression Die Forgings / Precision Forgings: Impression die forgings and precision
forgings are further refinements of the blocker forgings. The finished part more
closely resembles the die impression e.g drop forging, Press forging rolling,
extortion.
2. Open Die Forgings / Hand Forgings: Open die forgings or hand forgings are made
with repeated blows in an open die, where the operator manipulates the work piece
in the die. The finished product is a rough approximation of the die. This is a
traditional blacksmith does, and is an old manufacturing process.
A blacksmith is a person who creates objects from iron or steel by forging the metal;
i.e., by using tools to hammer, fueled by natural gas, coal, charcoal, or coke .Bend,
and cut. Blacksmiths produce things like wrought iron gates, grills, railings, light
fixtures, furniture, agricultural implements, decorative and religious items, cooking
utensils, horseshoes and weapons.
TOOLS AND EQUIPMENTS
The basic tools and other equipments used in hand forging are describe below
FORGE OR OPEN-HEARTH - It is made of cast iron or cast steel its carries coal,
charcoal, cotton waste, it is provide some fire bricks. Air is provided through a pipe
connected from a blower. A valve is containing for air controlling purpose. A water
tank in front of it for quenching purpose.


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POKER It is made of mild steel. It is use for loosening the clinker and knows the proper
position of the heated metal

Poker
SHOVEL It is used for fueling purpose.

Shovel
ANVIL It is supporting tool. It is made of wrought iron or cast steel. It is used for
cutting, punching, bending, supporting etc.


Anvil
SWAGE BLOCK It is a supporting tool. It is made of cast steel or cast iron. A no. of
slots and hole are contain in its of different shapes and size. It is used for forming
different shape and supporting punching holes.



Swage block
TONGS Tong is a holding tool. It is used for hold the hot metal or work piece at the
time of blacksmithing. It is made of mild steel, it has different types according the inside
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shape of jaw for purpose of different work. e.g Open mouth flat tong, close mouth flat
tong, Round tong, Side tong, pick- up tong, square hollow tong

Pickup Tong Round tong Flat tong

HAMMER - These are striking tools; it is used for striking purpose. It has 2 types
(hand hammer, Sledge hammer, ) power hammer is used for big work like industries.
Also hand hammer is different types e.g. Ball peen, cross peen, straight peen, claw.

Ball peen sledge claw cross peen Straight hammer
CHISEL - It a cutting tools it is used for cutting purpose. These are two types Cold and
Hot chisel. Cold chisel used for cut the metal at cold condition. It is cutting angle 60
0
.
In hot chisel cut the metal in hot condition, it is cutting is 30
0
.

Hot chisel Cold chisel
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HARDIE - This is used in conjunction with a bottom cutting. its another name is bottom
chisel. It is made of high carbon steel.

Bottom Top
FULLER - This is used for making necks reducing the cross section of a job and also
drawing out purpose. It is made of high carbon steel.

Bottom Top
PUNCH Punches are used marking dotted point and making holes in metal hot condition

Punch
DRIFT Drift is similar as punch but it is used for making in large holes metal in hot
condition.

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Drift
FLATTER flatter is used for leveling and finishing and flat surface after drawing out and
other forging operation.

Flatter
BOLSTER these are also known as heading tools are used for shaping bosses and
forming heads on ends of rod, bar etc.


Bolster
SWAGE Swages are used increasing the length of circular rod or finishing the circular
surface of a job after forging.

Bottom Top

STEEL RULE It is used for measuring purpose,

Steel rule
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CALIIIPER Clipper are two types inside caliper and outside caliper its generally used
diameter, thickness and widths.

Inside out side
TRY SQUARE it is used for measuring and marking the right angle

Try square
DIVIDER Divider is used in measuring the distance between two points and draw the
circle, arc etc.

Divider
LEG VICE It is generally used in blacksmith shop. Hot job is fastened in it and
blacksmith operation.



Leg vice
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OPERATION
The blacksmith operation are generally following types
DRAWING -OUT
Drawing lengthens the metal by reducing one or both of the other two dimensions. As the
depth is reduced, the width narrowed, or both the piece is lengthened or "drawn out".

As an example of drawing, a smith making a chisel might flatten a square bar of steel
BENDING
Heating steel to a "forging heat" allows bending as if was hard plasticine: it takes

significant but not Herculean effort. Bending can be done with the hammer over the horn
or edge of the anvil
UPSETTING
Upsetting is the process of making metal thicker in one dimension through shortening in
the other. One form is by heating the end of a rod and then hammering on it as one would
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drive a nail: the rod gets shorter, and the hot part widens.
PUNCHING

Punching may be done to create a decorative pattern, or to make a hole. For example, in
preparation for making a hammerhead
FULLERING

Fullering the metal along the length of the job is done by working separate section. In this
case axis of the job is positioned perpendicular to width of the flat die.
FORGE WELDING
It is the process of joining the two surface of metal under pressure after they are heated to
the correct temperature.