Workshop Practice

(ME-105 )
DE-42 Mechatronics
Syndicate – A

Lab Title: Forging

Week No: 4

Names of Group Members as per CMS:

1. NC/PC/GC ibrahim nouman Reg #359584

2. NC/PC/GC Muhammad Rashid Ali Khan Reg #335681

Submitted to: LE Adnan Shujah

1. Name of the Lab: Forging.
2. Objectives:
 Shop Orientation,
 Introduction to Tools &their use.
 Up-setting on a piece of mild steel as per drawing.
3. Safety instructions for specific lab:
Essential safety equipment consists of:
 An apron, for protection from sparks.
 Protective gloves and earmuffs.
 Avoid wearing clothing that might get caught in moving or rotating
parts. Long sleeves of shirts, long hair, necktie and jewelry are
definite hazards in the shop.
 Wear safety goggles when working in areas, where sparks or chips of
metal are flying.
4. Equipment /Tools Used:
 Job (work piece) is made up of mild steel.
 Furnace, to heat metals for forging. The furnace works by burning
coal.
 Poker Smith.
 Tongs are used to grip, lift and rotate red-hot metal.
1. Tong round, to hold a round job.
2. Tong flat, to hold a flat job.

 Anvil, a base for forging metals.

 Forging presses.

Drop hammers are of two types;

1. Gravity drop hammers.
2. Power drop hammers.
 Forging hammers for smith forging, i.e. flatter and sledge hammer.
 5. Procedure: -Analysis/Results:
I. First step is to be vary of all safety precautions and to wear
necessary protective gear.
II. Then pick the work piece (Metal) and by using a tong and heat it in the
furnace, also known as hearth.
III. In Hammer forging the red-hot metal from the furnace is placed on
an anvil for forging to give it a desired shape.
IV. In Machine forging metals are placed in large drop hammers to give
them the desired shape. This includes Gravity Drops and Power
Drops.
V. Basic types of forging are given as;
1. Open-Die forging.
2. Impression-Die forging.
3. Closed-Die forging.

Open-Die forging;

It is also called smith forging, therefore there are no boundaries and

no flashes are produced.

Impression-Die forging;

There are 2 parts of Impression-Die forging i.e. upper die and lower
die. Place the metal in lower die and your desired shape will be obtained after
the forging process. Flashes are produced in impression-die forging.

Closed –Die forging;

It is like impression-die forging but the flashes are removed and the
final output obtained it clean.

Note: Flash is the extra material pushed away from the active site.
Process for manufacturing a chisel;
1. First prepare a fire in the furnace to heat the work piece in.
2. Take the work piece and place it in the furnace by using a tong till it
becomes red-hot.
3. Heating temperature of mild steel is from 750C to 950C and melting
temperature is from 1500C to 1600C.
4. After the work piece has been heated take it out of the furnace by using
a poker smith and tong and place it on an anvil.
5. Place the flat hammer on the work piece and hit it with the sledge
hammer to deform the work piece into desired shape while work piece is
red-hot.
6. After deforming the work piece place it in water to cool it down.
7. A grinder is used afterwards to sharpen the work piece.
8. The final product obtained is a chisel which is used to remove some part
of stone or wood by placing its sharp edge against them.