DESIGN AND FABRICATION OF AUTOMATED

PORTABLE HAMMERING MACHINE

ABSTRACT:

THE AIM OF THE PROJECT IS TO FABRICATE THE AUTOMATED PORTABLE

HAMMERING MACHINE. HAMMERS ARE MECHANICAL FORGING HAMMERS

THAT USE A NON-MUSCULAR POWER SOURCE TO RAISE THE HAMMER

PREPARATORY TO STRIKING, AND ACCELERATE IT ONTO THE WORK

BEING HAMMERED. ALSO CALLED "OPEN DIE POWER FORGING

HAMMERS." THEY HAVE BEEN USED BY BLACKSMITHS, BLADE SMITHS,

METALWORKERS, AND MANUFACTURERS HAVING REPLACED TRIP

HAMMERS. THIS PROJECT HAS A HIGH ADVANTAGE OF EASY AND

SIMPLE OPERATION. THIS ALSO REDUCE THE MANUAL WORK A TYPICAL

CAM OPERATED HAMMER CONSISTS OF A FRAME, AN ANVIL, AND A

RECIPROCATING RAM HOLDING A HAMMER HEAD OR DIE. THE

WORKPIECE IS PLACED ON THE LOWER ANVIL OR DIE AND THE HEAD OR

UPPER DIE STRIKES THE WORKPIECE. THE CAM OPERATED HAMMER IS

A DIRECT DESCENDANT OF THE TRIP HAMMER, DIFFERING IN THAT THE

CAM OPERATED HAMMER STORES POTENTIAL ENERGY IN AN

ARRANGEMENT OF MECHANICAL LINKAGES AND SPRINGS, IN

HAMMERED AIR, OR STEAM, AND BY THE FACT THAT IT ACCELERATES

THE RAM ON THE DOWNWARD STROKE. THIS PROVIDES MORE FORCE

THAN SIMPLY ALLOWING THE WEIGHT TO FALL. EARLIER DESIGNS LIKE

TRIP HAMMER, STEAM DROP HAMMERS, BOARD OR STRAP HAMMERS,

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USE THE POWER SOURCE TO RAISE THE RAM, BUT LET ITS FALL BE

PROPELLED SOLELY BY GRAVITY.

CHAPTER – I

INTRODUCTION

Sheet metal fabrication is a classification of manufacturing

processes that shape a piece of sheet metal into the desired part through

material removal and/or material deformation. Sheet metal, which acts as

the workpiece in these processes, is one of the most common forms of

raw material stock. The material thickness that classifies a workpiece as

sheet metal is not clearly defined. However, sheet metal is generally

considered to be a piece of stock between 0.006 and 0.25 mm thick. A

piece of metal much thinner is considered to be "foil" and any thicker is referred to as

a "plate". The thickness of a piece of sheet metal is often referred to as its gauge, a

number typically ranging from 3 to 38. A higher gauge indicates a thinner piece of

sheet metal, with exact dimensions that depend on the material. Sheet metal stock is

available in a wide variety of materials, which include the following:

 Aluminum  Stainless steel

 Brass  Steel

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  Bronze
 Tin
 Copper
 Titanium
 Magnesium
 Zinc
 Nickel
Sheet metal can be cut, bent, and stretched into a nearly any shape.

Material removal processes can create holes and cutouts in any 2D

geometric shape. Deformation processes can bend the sheet numerous

times to different angles or stretch the sheet to create complex contours.

The size of sheet metal parts can range from a small washer or bracket, to

midsize enclosures for home appliances, to large airplane wings. These

parts are found in a variety of industries, such as aircraft, automotive,

construction, consumer products, HVAC, and furniture.

Sheet metal fabrication processes can mostly be placed into two

categories - forming and cutting. Forming processes are those in which

the applied force causes the material to plastically deform, but not to fail.

Such processes are able to bend or stretch the sheet into the desired

shape. Cutting processes are those in which the applied force causes the

material to fail and separate, allowing the material to be cut or removed.

Most cutting processes are performed by applying a great enough

shearing force to separate the material, and are therefore sometimes

3
referred to as shearing processes. Other cutting processes remove

material by using heat or abrasion, instead of shearing forces.

 Forming

 Bending

 Roll forming

 Spinning

 Deep Drawing

 Stretch forming

 Cutting with shear

 Shearing

 Blanking

 Bending

 Cutting without shear

 Laser beam cutting

 Plasma cutting

 Water jet cutting

4
 Sheet metal forming processes are those in which force is applied

to a piece of sheet metal to modify its geometry rather than remove any

material. The applied force stresses the metal beyond its yield strength,

causing the material to plastically deform, but not to fail. By doing so,

the sheet can be bent or stretched into a variety of complex shapes. Sheet

metal forming processes include the following:

Bending is a metal forming process in which a force is applied to a

piece of sheet metal, causing it to bend at an angle and form the desired

shape. A bending operation causes deformation along one axis, but a

sequence of several different operations can be performed to create a

complex part. Bent parts can be quite small, such as a bracket, or up to 20

feet in length, such as a large enclosure or chassis. A bend can be

characterized by several different parameters, shown in the image below.

Roll forming

Roll forming, sometimes spelled rollforming, is a metal forming

process in which sheet metal is progressively shaped through a series of

bending operations. The process is performed on a roll forming line in

which the sheet metal stock is fed through a series of roll stations. Each

station has a roller, referred to as a roller die, positioned on both sides of

5
the sheet. The shape and size of the roller die may be unique to that

station, or several identical roller dies may be used in different positions.

The roller dies may be above and below the sheet, along the sides, at an

angle, etc. As the sheet is forced through the roller dies in each roll

station, it plastically deforms and bends. Each roll station performs one

stage in the complete bending of the sheet to form the desired part. The

roller dies are lubricated to reduce friction between the die and the sheet,

thus reducing the tool wear. Also, lubricant can allow for a higher

production rate, which will also depend on the material thickness,

number of roll stations, and radius of each bend. The roll forming line

can also include other sheet metal fabrication operations before or after

the roll forming, such as Bendingor shearing.

Design and operation

A typical cam operated hammer consists of a frame, an anvil, and a

reciprocating ram holding a hammer head or die. The workpiece is

placed on the lower anvil or die and the head or upper die strikes the

workpiece. The cam operated hammer is a direct descendant of the trip

hammer, differing in that the cam operated hammer stores potential

energy in an arrangement of mechanical linkages and springs, in

comhammered air, or steam, and by the fact that it accelerates the ram on

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the downward stroke. This provides more force than simply allowing the

weight to fall. Earlier designs like trip hammer, steam drop hammers,

board or strap hammers, use the power source to raise the ram, but let its

fall be propelled solely by gravity.

Cam operated hammers are rated by weight of moving parts that

act directly on the work piece. This includes the weight of the parts that

may consist of upper die, ram, mechanical linkage arms and spring(s) or

ram, piston, and associated connecting rod(s). Specific design elements

are dictated by the power source. The largest cam operated hammer was

powered by steam and was rated at 125 short tons (113 t).[1]

Types

Cam operated hammers are generally categorized by their power

source.

Steam

Steam hammer

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 Steam hammers use steam to drive the hammer. These tended to be

the largest models as the great energy of steam was needed to operate

them. Locomotive works was one location such large hammers were

needed. The workpieces were sometimes so large it required an overhead

crane and several men to position the piece in the hammer, and a man to

operate the machine.

Mechanical

These hammers tended to be smaller and were operated by a single

man both holding the workpiece and operating the machine. The majority

of these mechanical linkage machines were powered by line shaft flat

belt systems or later electric motors that rotated a crank on the machine

that drove the ram.

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 CHARACTERISTICS OF MACHINE

The bending machine is characterized by parameters such as:

 Construction

 Mechanism of delivering power to the ram (mechanical, electro-

mechanical or hydraulic)

 Size of working area

 Single or multiple station

 Force rating (for example, 20 tons)

 The type of tool shop and its capacity (e.g., store revolving type,

capacity 34 tool)

 Speed or productivity (typically characterized by the speed of

strokes with a step movement of 25 and 1 mm)

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 Speed of movement without shock (speed-load displacement)

 Maximum weight of workpiece

 Safety features

 Power consumption

 The type of software

NEED FOR PROJECT

 To achieve mass production

 To reduce manpower

 To increase the efficiency of the plant

 To reduce the work load

 To reduce the production cost

 To reduce the production time

 To reduce the material handling

 To reduce the fatigue of workers

 To achieve good product quality

 Less Maintenance

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 TOOLS

A die is a specialized tool used in manufacturing industries to cut

or shape material using a hammer. Like molds, dies are generally
customized to the item they are used to create. Products made with dies
range from simple paper clips to complex pieces used in advanced
technology.

Types of Bending Tools

A bending tool must be decided depending on the shape and severity of

bend. Following are the different types of bending commonly used for
precision sheet metal bending.

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"V" Bending
"L" Bending
"U" Bending

V Bending Dies

V Bending dies have the simplest bending die design. The bending
die have the shape of V with an included angle of 90° in most cases. The
bending punch is also in the shape of V, but with a lesser angle than the
die. And in some cases the bending punches may have a relief after a
straight land to a certain length.

L Bending Dies

L Bending dies are used for 90° bending. L bending dies can

produce more accurate and consistent parts compared to V bending. This

is due to the presence of spring loaded clamping pads which will hold

sheet metal closer to the bending line and then the bending punch pushes

the sheet metal into the bending die along the bending line. L bending

dies can also be used for bending angles smaller than 90° by providing

suitable punch profiles and by controlling the travel of the punch. We

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may need a series of L bending operations to be done in a progressive

metal stamping die to produce complex parts.

Die components

The main components for Die Toolsets are:

 Die block - This is the main part that all the other parts are

attached to.

 Punch plate - This part holds and supports the different punches in

place.

 Blank punch - This part along with the Bending Die produces the

curved part.

 Stripper plate - This is used to hold the material down on the

Blank/ Pierce Die and strip the material off the punches.

 Pilot - This is used to keep the material being worked on in

position.

 Guide / Back gage / Finger stop - These parts are all use to make

sure that the material being worked on always goes in the same

position, within the die, as the last one.

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 Setting Block - This part is used to control the depth that the punch

does into the die.

Die operations and types

Die operations are often named after the specific type of die that

performs the operation. For example a bending operation is performed by

a bending die. Operations are not limited to one specific die as some dies

may incorporate multiple operation types:

Hammer with bending die

Bending

The bending operation is the act of bending blanks at a

predetermined angle. An example would be an "L" bracket which is a

straight piece of metal bent at a 90° angle. The main difference between a

forming operation and a bending operation is the bending operation

creates a straight line bend (such as a corner in a box) as where a form

operation may create a curved bend (such as the bottom of a drink can).

Blanking

A blanking die produces a flat piece of material by cutting the

desired shape in one operation. The finish part is referred to as a blank.

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Generally a blanking die may only cut the outside contour of a part, often

used for parts with no internal features.

Three benefits to die blanking are:

1. Accuracy. A properly sharpened die, with the correct

amount of clearance between the punch and die, will produce a part that

holds close dimensional tolerances in relationship to the parts edges.

2. Appearance. Since the part is blanked in one operation, the

finish edges of the part produces a uniform appearance as opposed to

varying degrees of burnishing from multiple operations.

3. Flatness. Due to the even comhammerion of the blanking

process, the end result is a flat part that may retain a specific level of

flatness for additional manufacturing operations.

Broaching

The process of removing material through the use of multiple

cutting teeth, with each tooth cutting behind the other. A broaching die is

often used to remove material from parts that are too thick for shaving.

Bulging

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 A bulging die expands the closed end of tube through the use of

two types of bulging dies. Similar to the way a chefs hat bulges out at the

top from the cylindrical band around the chefs head.

1. Bulging fluid dies: Uses water or oil as a vehicle to expand

the part.

2. Bulging rubber dies: Uses a rubber pad or block under

hammerure to move the wall of a workpiece.

Coining

It is similar to forming with the main difference being that a

coining die may form completely different features on either face of the

blank, these features being transferred from the face of the punch or die

respectively. The coining die and punch flow the metal by squeezing the

blank within a confined area, instead of bending the blank. For example:

an Olympic medal that was formed from a coining die may have a flat

surface on the back and a raised feature on the front. If the medal was

formed (or embossed), the surface on the back would be the reverse

image of the front.

Compound operations:

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 Compound dies perform multiple operations on the part. The

compound operation is the act of implementing more than one operation

during the hammer cycle.

Compound die:

A type of die that has the die block (matrix) mounted on a punch

plate with perforators in the upper die with the inner punch mounted in

the lower die set. An inverted type of blanking die that punches upwards,

leaving the part sitting on the lower punch (after being shed from the

upper matrix on the hammer return stroke) instead of blanking the part

through. A compound die allows the cutting of internal and external part

features on a single hammer stroke.

Curling: The curling operation is used to roll the material into a curved

shape. A door hinge is an example of a part created by a curling die.

Cut off: Cut off dies are used to cut off excess material from a finished

end of a part or to cut off a predetermined length of material strip for

additional operations.

Extruding: Extruding is the act of severely deforming blanks of metal

called slugs into finished parts such as an aluminum I-beam. Extrusion

dies use extremely high hammerure from the punch to squeeze the metal

17
out into the desired form. The difference between cold forming and

extrusion is extruded parts do not take shape of the punch.

Forming: Forming dies bend the blank along a curved surface..

Cold forming (cold heading): Cold forming is similar to extruding in

that it squeezes the blank material but cold forming uses the punch and

the die to create the desired form, extruding does not.

Roll Forming Stand

 Roll forming: a continuous bending operation in which

sheet or strip metal is gradually formed in tandem sets of rollers until the

desired cross-sectional configuration is obtained. Roll forming is ideal

for producing parts with long lengths or in large quantities.

 Horning: A horning die provides an arbor or horn which the

parts are place for secondary operations.

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  Hydroforming: Forming of tubular part from simpler tubes

with high water hammerure.

 Pancake die: A Pancake die is a simple type of

manufacturing die that performs blanking and/or piercing. While many

dies perform complex procedures simultaneously, a pancake die may

only perform one simple procedure with the finished product being

removed by hand.

 Piercing: The piercing operation is used to pierce holes in

stampings.

 Progressive die: Progressive dies provide different stations

for operations to be performed. A common practice is to move the

material through the die so it is progressively modified at each station

until the final operation ejects a finished part.

 Shaving: The shaving operation removes a small amount of

material from the edges of the part to improve the edges finish or part

accuracy. (Compare to Trimming).

 Side cam die: Side cams transform vertical motion from the

hammer ram into horizontal or angular motion.

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  Sub hammer operation: Sub-hammer dies blank and/or

form small watch, clock, and instrument parts.

 Swaging: Swaging (necking) is the process of "necking

down" a feature on a part. Swaging is the opposite of bulging as it

reduces the size of the part. The end of a shell casing that captures the

bullet is an example of swaging.

 Trimming: Trimming dies cut away excess or unwanted

irregular features from a part, they are usually the last operation

performed.

Steel-rule die

Steel-rule dies, also known as cookie-cutter dies, are used to

cut sheet metal and softer webs, such as plastics, wood, cork, felt, fabrics,

and cardboard. The cutting surface of the die is the edge of hardened

steel strips, known as steel rule. These steel rules are usually located

using saw-cut grooves in plywood. The mating die can be a flat pieces of

hardwood or steel, a male shape that matches the workpiece profile, or it

can have a matching groove that allows the rule to nest into. Rubber

strips are wedged in with the steel rule to act as the stripper plate; the

rubber comhammeres on the down-stroke and on the up-stroke it pushes

20
the workpiece out of the die. The main advantage of steel-rule dies is the

low cost to make them, as compared to solid dies; however, they are not

as robust as solid dies, so they usually only used for short production

runs.

Rotary die

In the broadest sense, a rotary die is a circular shaped die that may

be used in any manufacturing field. However, it most commonly refers to

circular shaped dies used to process soft webs, such as paper and

cardboard. Two dies are used, one has cutting and creasing rules, while

the other acts as the anvil. Rotary dies are faster than flat dies, but not as

accurate.

Wire pulling

Wire-making dies have a hole through the middle of them. A wire

or rod of steel, copper, other metals, or alloy enters into one side and is

lubricated and reduced in size. The leading tip of the wire is usually

pointed in the process. The tip of the wire is then guided into the die and

rolled onto a block on the opposite side. The block provides the power to

pull the wire through the die.

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 The die is divided into several different sections. First is an

entrance angle that guides the wire into the die. Next is the approach

angle, which brings the wire to the nib, which facilitates the reduction.

Next is the bearing and the back relief. Lubrication is added at the

entrance angle. The lube can be in powdered soap form. If the lubricant is

soap, the friction of the drawing of wire heats the soap to liquid form and

coats the wire. The wire should never actually come in contact with the

die. A thin coat of lubricant should prevent the metal to metal contact.

For pulling a substantial rod down to a fine wire a series of several

dies is used to obtain progressive reduction of diameter in stages.

Standard wire gauges used to refer to the number of dies through

which the wire had been pulled. Thus, a higher-numbered wire gauge

meant a thinner wire. Typical telephone wires were 22-gauge, while main

power cables might be 3- or 4-gauge.

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 CAM OPERATED HAMMERING WORKS

Forging is a manufacturing process involving the shaping of metal

using localized comhammerive forces. The blows are delivered with a

hammer (often a cam operated hammer) or a die. Forging is often

classified according to the temperature at which it is performed: cold

forging (a type of cold working), warm forging, or hot forging (a type of

hot working). For the latter two, the metal is heated, usually in a forge.

Forged parts can range in weight from less than a kilogram to hundreds

of metric tons. Forging has been done by smiths for millennia; the

traditional products were kitchenware, hardware, hand tools, edged

weapons, and jewellery. Since the Industrial Revolution, forged parts are

widely used in mechanisms and machines wherever a component

requires high strength; such forgings usually require further processing

(such as machining) to achieve a finished part. Today, forging is a major

worldwide industry.

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 Forging is one of the oldest known metalworking

processes.Traditionally, forging was performed by a smith using hammer

and anvil, though introducing water power to the production and working

of iron in the 12th century allowed the use of large trip hammers or cam

operated hammers that exponentially increased the amount and size of

iron that could be produced and forged easily. The smithy or forge has

evolved over centuries to become a facility with engineered processes,

production equipment, tooling, raw materials and products to meet the

demands of modern industry.

In modern times, industrial forging is done either with hammeres

or with hammers powered by comhammered air, electricity, hydraulics or

steam. These hammers may have reciprocating weights in the thousands

of pounds. Smaller cam operated hammers, 500 lb (230 kg) or less

reciprocating weight, and hydraulic hammeres are common in art

smithies as well. Some steam hammers remain in use, but they became

obsolete with the availability of the other, more convenient, power

sources.

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 Forging can produce a piece that is stronger than an equivalent cast

or machined part. As the metal is shaped during the forging process, its

internal grain deforms to follow the general shape of the part. As a result,

the grain is continuous throughout the part, giving rise to a piece with

improved strength characteristics.[4] Additionally, forgings can target a

lower total cost when compared to a casting or fabrication. When you

consider all the costs that are involved in a product’s lifecycle from

procurement to lead time to rework, then factor in the costs of scrap,

downtime and further quality issues, the long-term benefits of forgings

can outweigh the short-term cost-savings that castings or fabrications

might offer.

Some metals may be forged cold, but iron and steel are almost

always hot forged. Hot forging prevents the work hardening that would

result from cold forging, which would increase the difficulty of

performing secondary machining operations on the piece. Also, while

work hardening may be desirable in some circumstances, other methods

of hardening the piece, such as heat treating, are generally more

economical and more controllable. Alloys that are amenable to

25
precipitation hardening, such as most aluminium alloys and titanium, can

be hot forged, followed by hardening.[citation needed]

Production forging involves significant capital expenditure for

machinery, tooling, facilities and personnel. In the case of hot forging, a

high-temperature furnace (sometimes referred to as the forge) is required

to heat ingots or billets. Owing to the massiveness of large forging

hammers and hammeres and the parts they can produce, as well as the

dangers inherent in working with hot metal, a special building is

frequently required to house the operation. In the case of drop forging

operations, provisions must be made to absorb the shock and vibration

generated by the hammer. Most forging operations use metal-forming

dies, which must be precisely machined and carefully heat-treated to

correctly shape the workpiece, as well as to withstand the tremendous

forces involved.

Processes

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 A cross-section of a forged connecting rod that has been etched to

show the grain flow

There are many different kinds of forging processes available,

however they can be grouped into three main classes

Drawn out: length increases, cross-section decreases

Upset: length decreases, cross-section increases

Squeezed in closed comhammerion dies: produces multidirectional

flow

Common forging processes include: roll forging, swaging,

cogging, open-die forging, imhammerion-die forging, hammer forging,

automatic hot forging and upsetting.

Temperature

All of the following forging processes can be performed at various

temperatures, however they are generally classified by whether the metal

27
temperature is above or below the recrystallization temperature. If the

temperature is above the material's recrystallization temperature it is

deemed hot forging; if the temperature is below the material's

recrystallization temperature but above 30% of the recrystallization

temperature (on an absolute scale) it is deemed warm forging; if below

30% of the recrystallization temperature (usually room temperature) then

it is deemed cold forging. The main advantage of hot forging is that it can

be done faster and more precise, and as the metal is deformed work

hardening effects are negated by the recrystallization process. Cold

forging typically results in work hardening of the piece.

Drop forging

Drop forging is a forging process where a hammer is raised and

then "dropped" onto the workpiece to deform it according to the shape of

the die. There are two types of drop forging: open-die drop forging and

closed-die drop forging. As the names imply, the difference is in the

shape of the die, with the former not fully enclosing the workpiece, while

the latter does.

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 Open-die drop forging

Open-die drop forging (with two dies) of an ingot to be further

processed into a wheel

Open-die forging is also known as smith forging. In open-die

forging, a hammer strikes and deforms the workpiece, which is placed on

a stationary anvil. Open-die forging gets its name from the fact that the

dies (the surfaces that are in contact with the workpiece) do not enclose

the workpiece, allowing it to flow except where contacted by the dies.

The operator therefore needs to orient and position the workpiece to get

the desired shape. The dies are usually flat in shape, but some have a

specially shaped surface for specialized operations. For example, a die

may have a round, concave, or convex surface or be a tool to form holes

or be a cut-off tool.[9] Open-die forgings can be worked into shapes

which include discs, hubs, blocks, shafts (including step shafts or with

flanges), sleeves, cylinders, flats, hexes, rounds, plate, and some custom

shapes.[10] Open-die forging lends itself to short runs and is appropriate

29
for art smithing and custom work. In some cases, open-die forging may

be employed to rough-shape ingots to prepare them for subsequent

operations. Open-die forging may also orient the grain to increase

strength in the required direction.

"Cogging" is the successive deformation of a bar along its length

using an open-die drop forge. It is commonly used to work a piece of raw

material to the proper thickness. Once the proper thickness is achieved

the proper width is achieved via "edging" "Edging" is the process of

concentrating material using a concave shaped open-die. The process is

called "edging" because it is usually carried out on the ends of the

workpiece. "Fullering" is a similar process that thins out sections of the

forging using a convex shaped die. These processes prepare the

workpieces for further forging processes.

Imhammerion-die forging

Imhammerion-die forging is also called "closed-die forging". In

imhammerion-die forging, the metal is placed in a die resembling a mold,

which is attached to an anvil. Usually, the hammer die is shaped as well.

The hammer is then dropped on the workpiece, causing the metal to flow

and fill the die cavities. The hammer is generally in contact with the

30
workpiece on the scale of milliseconds. Depending on the size and

complexity of the part, the hammer may be dropped multiple times in

quick succession. Excess metal is squeezed out of the die cavities,

forming what is referred to as "flash". The flash cools more rapidly than

the rest of the material; this cool metal is stronger than the metal in the

die, so it helps prevent more flash from forming. This also forces the

metal to completely fill the die cavity. After forging, the flash is removed.

In commercial imhammerion-die forging, the workpiece is usually

moved through a series of cavities in a die to get from an ingot to the

final form. The first imhammerion is used to distribute the metal into the

rough shape in accordance to the needs of later cavities; this

imhammerion is called an "edging", "fullering", or "bending"

imhammerion. The following cavities are called "blocking" cavities, in

which the piece is working into a shape that more closely resembles the

final product. These stages usually impart the workpiece with generous

bends and large fillets. The final shape is forged in a "final" or "finisher"

imhammerion cavity. If there is only a short run of parts to be done, then

it may be more economical for the die to lack a final imhammerion

cavity and instead machine the final features.[4] Imhammerion-die

forging has been improved in recent years through increased automation

31
which includes induction heating, mechanical feeding, positioning and

manipulation, and the direct heat treatment of parts after forging. Design

of imhammerion-die and tooling

Forging dies are usually made of high-alloy or tool steel. Dies

must be impact resistant, wear resistant, maintain strength at high

temperatures, and have the ability to withstand cycles of rapid heating

and cooling. In order to produce a better, more economical die the

following standards are maintained:

The dies part along a single, flat plane whenever possible. If not,

the parting plane follows the contour of the part.

The parting surface is a plane through the center of the forging and

not near an upper or lower edge.

Adequate draft is provided; usually at least 3° for aluminium and

5° to 7° for steel.

Generous fillets and radii are used.

Ribs are low and wide.

32
 The various sections are balanced to avoid extreme difference in

metal flow.

Full advantage is taken of fiber flow lines.

Dimensional tolerances are not closer than necessary.

The dimensional tolerances of a steel part produced using the

imhammerion-die forging method are outlined in the table below. The

dimensions across the parting plane are affected by the closure of the

dies, and are therefore dependent on die wear and the thickness of the

final flash. Dimensions that are completely contained within a single die

segment or half can be maintained at a significantly greater level of

accuracy.

Hammer WORK

Hammer forging works by slowly applying a continuous

hammerure or force, which differs from the near-instantaneous impact of

drop-hammer forging. The amount of time the dies are in contact with the

33
workpiece is measured in seconds (as compared to the milliseconds of

drop-hammer forges). The hammer forging operation can be done either

cold or hot.

The main advantage of hammer forging, as compared to drop-

hammer forging, is its ability to deform the complete workpiece. Drop-

hammer forging usually only deforms the surfaces of the work piece in

contact with the hammer and anvil; the interior of the workpiece will stay

relatively undeformed. Another advantage to the process includes the

knowledge of the new part's strain rate. We specifically know what kind

of strain can be put on the part, because the comhammerion rate of the

hammer forging operation is controlled.

There are a few disadvantages to this process, most stemming from

the workpiece being in contact with the dies for such an extended period

of time. The operation is a time-consuming process due to the amount

and length of steps. The workpiece will cool faster because the dies are in

contact with workpiece; the dies facilitate drastically more heat transfer

34
than the surrounding atmosphere. As the workpiece cools it becomes

stronger and less ductile, which may induce cracking if deformation

continues. Therefore, heated dies are usually used to reduce heat loss,

promote surface flow, and enable the production of finer details and

closer tolerances. The workpiece may also need to be reheated.

When done in high productivity, hammer forging is more

economical than hammer forging. The operation also creates closer

tolerances. In hammer forging a lot of the work is absorbed by the

machinery, when in hammer forging, the greater percentage of work is

used in the work piece. Another advantage is that the operation can be

used to create any size part because there is no limit to the size of the

hammer forging machine. New hammer forging techniques have been

able to create a higher degree of mechanical and orientation integrity. By

the constraint of oxidation to the outer layers of the part, reduced levels

of microcracking occur in the finished part.

35
 Hammer forging can be used to perform all types of forging,

including open-die and imhammerion-die forging. Imhammerion-die

hammer forging usually requires less draft than drop forging and has

better dimensional accuracy. Also, hammer forgings can often be done in

one closing of the dies, allowing for easy automation.

Upset forging

Upset forging increases the diameter of the workpiece by

comhammering its length. Based on number of pieces produced, this is

the most widely used forging process.A few examples of common parts

produced using the upset forging process are engine valves, couplings,

bolts, screws, and other fasteners.

Upset forging is usually done in special high-speed machines

called crank hammeres. The machines are usually set up to work in the

horizontal plane, to facilitate the quick exchange of workpieces from one

station to the next, but upsetting can also be done in a vertical crank

hammer or a hydraulic hammer. The initial workpiece is usually wire or

36
rod, but some machines can accept bars up to 25 cm (9.8 in) in diameter

and a capacity of over 1000 tons. The standard upsetting machine

employs split dies that contain multiple cavities. The dies open enough to

allow the workpiece to move from one cavity to the next; the dies then

close and the heading tool, or ram, then moves longitudinally against the

bar, upsetting it into the cavity. If all of the cavities are utilized on every

cycle, then a finished part will be produced with every cycle, which

makes this process advantageous for mass production.

These rules must be followed when designing parts to be upset

forged:

The length of unsupported metal that can be upset in one blow

without injurious buckling should be limited to three times the diameter

of the bar.

Lengths of stock greater than three times the diameter may be

upset successfully, provided that the diameter of the upset is not more

than 1.5 times the diameter of the stock.

37
 In an upset requiring stock length greater than three times the

diameter of the stock, and where the diameter of the cavity is not more

than 1.5 times the diameter of the stock, the length of unsupported metal

beyond the face of the die must not exceed the diameter of the bar.

Automatic hot forging

The automatic hot forging process involves feeding mill-length

steel bars (typically 7 m (23 ft) long) into one end of the machine at room

temperature and hot forged products emerge from the other end. This all

occurs rapidly; small parts can be made at a rate of 180 parts per minute

(ppm) and larger can be made at a rate of 90 ppm. The parts can be solid

or hollow, round or symmetrical, up to 6 kg (13 lb), and up to 18 cm (7.1

in) in diameter. The main advantages to this process are its high output

rate and ability to accept low-cost materials. Little labor is required to

operate the machinery.

There is no flash produced so material savings are between 20 and

30% over conventional forging. The final product is a consistent 1,050

°C (1,920 °F) so air cooling will result in a part that is still easily

38
machinable (the advantage being the lack of annealing required after

forging). Tolerances are usually ±0.3 mm (0.012 in), surfaces are clean,

and draft angles are 0.5 to 1°. Tool life is nearly double that of

conventional forging because contact times are on the order of 0.06-

second. The downside is that this process is only feasible on smaller

symmetric parts and cost; the initial investment can be over $10 million,

so large quantities are required to justify this process.[18]

The process starts by heating the bar to 1,200 to 1,300 °C (2,190 to

2,370 °F) in less than 60 seconds using high-power induction coils. It is

then descaled with rollers, sheared into blanks, and transferred through

several successive forming stages, during which it is upset, preformed,

final forged, and pierced (if necessary). This process can also be coupled

with high-speed cold-forming operations. Generally, the cold forming

operation will do the finishing stage so that the advantages of cold-

working can be obtained, while maintaining the high speed of automatic

hot forging.

39
 Examples of parts made by this process are: wheel hub unit

bearings, transmission gears, tapered roller bearing races, stainless steel

coupling flanges, and neck rings for LP gas cylinders.Manual

transmission gears are an example of automatic hot forging used in

conjunction with cold working.

40
 CHAPTER-II

LITERATURE REVIEW

Before starting our work we have undergone through many

research papers which indicates that for a production based industries

machine installation is a tricky task as many factor being associated with

it such as power consumption (electricity bill per machine),

maintenance cost, no of units produced per machine i.e.capacity of

machine, time consumption and many more…. Some research papers

which have led us to approach to the idea of a machine which may give

solution to all these factors are as follows:

Heinrich Arnold1 November 2001: Rather long re-investment

cycles of about 15 years have created the notion that innovation in

the machine tool industry happens incrementally. But looking at its

recent history, the integration of digital controls technology and

computers into machine tools have hit the industry in three waves of

technology shocks. Most companies underestimated the impact of this

new technology. This article gives an overview of the history of the

machine tool industry since numerical controls were invented and

introduced and analyzes the disruptive character of this new technology

41
on the market. About 100 interviews were conducted with decision-

makers and industry experts who witnessed the development of the

industry over the last forty years. The study establishes a connection

between radical technological change, industry structure, and

competitive environment. It reveals a number of important occurrences

and interrelations that have so far gone unnoticed. Multi-Function

Operating Machine: A Conceptual Model

Dr. Toshimichi Moriwaki (2006): Recent trends in the machine

tool technologies are surveyed from the view points of high speed and

high performance machine tools, combined multifunctional machine

tools, ultra precision machine tools and advanced and intelligent control

technologies.

Frankfurt-am Main, 10 January 2011. : The crisis is over, but

selling machinery remains a tough business. Machine tools nowadays

have to be veritable “jack of all trades”, able to handle all kinds

of materials, to manage without any process materials as far as possible,

and be capable of adapting to new job profiles with maximized

flexibility. Two highly respected experts on machining and forming from

42
Dortmund and Chemnitz report on what’s in store for machine tool

manufacturers and users.

Multi-purpose machines are the declarations of independence.

The trend towards the kind of multipurpose machining centers that

are able to cost efficiently handle a broad portfolio of products with

small batch sizes accelerated significantly during the crisis. “With a

multi-purpose machine, you’re less dependent on particular products

and sectors”, explains Biermann

43
 CHAPTER –III

METHODOLOGY

BLOCK DIAGRAM

Power

Rotation
DC motor Pulley Lever ram

Hammer

Finished job

44
 The hammer machine consists of column in which the lead screw

is provided. At one end of the lead screw handle of the hammeringtool is

attached. Another tools is fixed on the based plate. The hammer machine

consists of a base plate in which the work piece is placed. When the

handle is rotated the lead screw moves down and the bending tool

hammer the sheet and the sheet metal is bended. Different size & shape

of the bend can be bended using various tools. Automatic bending

machine consists of an electric motor and a frame with lead screw. The

sheet is fitted in the vice. When the motor switched gets on the rotary

motion of the motor is converted into reciprocating motion by means of

an gear and lead screw arrangement. A hammer is attached at the end of

the lead screw which bends the sheet metal.

45
 Precision sheet metal bending is not always easy operation. Poor

bending tool design and manufacturing can result in the following

bending defects.

1. Insufficient angle on bend part due to spring back

2. Scratch mark on part

3. Thinning of sheet metal at bending area

 In order to avoid these common defects try one of the following

tips mentioned below.

 Choose the correct bending operation. L bending is more accurate

than V bending in most cases.

 Verify the clearance between bending punch and die. There should

be a clearance of at least one sheet thickness+10% of Sheet

Thickness between bending punch and die.

 Provide adequate bending radius and polish it to high surface

finish. Bending radius is the radius on the bending die on which

the sheet material flows to form the desired profile. Hence it is

important to have very good surface finish at this area for smooth

flowing of material.

46
 Use corner setting if possible. In case of 90° bending, it is a good

idea to provide corner setting to eliminate spring back. Corner

setting is the process of coining the material to a small depth along

the bending line to overcome spring back. Please note that corner

setting may not be possible on very think sheet materials and sheet

metals with very high hardness.

47
3.1 DESIGN CALCULATION

48
 The required force to bend a piece of sheet metal using V-bending

a process in which a V-shaped punch hammers the sheet into a V-die.

The bending force can be calculated from the sheet thickness, die

opening, bend length, and the ultimate tensile strength of the material.

The die ratio may be entered to calculate the die opening, which is

typically 6 to 18times the sheet thickness. The calculated tonnage can

be used for the selection of a machine, such as a hammer brake, to

perform the bending operation.

F = BA x t x l x 

Where

F = Force in Newton

l = Bend length

t = Thickness of sheet

 = Ultimate tensile strength

F = BA x t x l x 

49
 F = (1.2) x. 0.004 x 0.01 x 410 x 106 = 19680 N

CHAPTER-IV

APPLICATIONS

 Workshops

 Automobile garages

 Mini industries

 shops

Advantages

 Low cost .

 Less maintenance.

 Simple in construction

 Operating Principle is very easy.

 Installation is simplified very much.

 It is possible to operate Manually/automatically by proving

On/Off switch.

 Higher accuracy

50
 CHAPTER V

CONCLUSION

With the idea on view, we have completed the project titled

“DESIGN AND FABRICATION OF AUTOMATIC HAMMERING

MACHINE”

This project is very much useful for bending the sheet metal. Thus

by means of the Bending machine, we can bend the sheet metal.

This is one of the most reliable and simple machine in the machine

shop in which many number of operations can done.

By means of this project, bending force also be calculated.

51
 REFERENCES

1. Production technology by P.C. Sharma

2. Todd, Robert H.; Allen, Dell K. Manufacturing Processes

Reference Guide

3. Industrial Hammer Inc., ISBN 0-8311-3049-0,

4. Colvin, Fred H. (1947), Sixty Years with Men and

Machines, McGraw-Hill,

5. Floud, Roderick C. (2006) [1976], The British Machine Tool

Industry,

6. Hounshell, David A. : The Development of Manufacturing

Technology in the United States,

7. Noble, David F. (1984), Forces of Production: A Social

History of Industrial Automation

52