CRAFTING OF KUKRI KNIFE

MANUFACTURING
SCIENCE AND TECHNOLOGY-I
Project submitted by-
Aakash Tiwari (21bme012)
Urvashi Lamba (21bme016)
Vansh Aggarwal (21bme017)
Neha Joshi (21bme021)
Adityansh Thakur(21bme028)
Gaurav Thapa (21bme084)
 What is a kukri knife?

A kukri knife, often referred to as a "khukri" knife, is a

distinctive and iconic traditional knife that originated in
Nepal. It is known for its unique curved blade and has been
widely associated with the Gurkha regiments and their
legendary service in various military conflicts. In this project
we will walk you through the step-by-step process of creating
a Kukri knife.

Uses of Kukri Knife

• Utility and General Cutting: The kukri knife can be used
for a wide range of cutting tasks, such as chopping,
slicing, and dicing. It's a practical tool for everyday utility.
• Agricultural and Farming: In rural areas, the kukri is often
used for agricultural purposes like cutting vegetation,
harvesting crops, and clearing fields.
• Kitchen and Cooking: Smaller, kitchen-oriented kukri
knives are used for food preparation including chopping
vegetables and other ingredients.
 Kukri Knife Design
some common features are:
• The blade is usually made of high carbon steel and has a single
edge that is sharpened along the concave side. The blade can
range from 10 to 18 inches in length and from 1.5 to 3 inches in
width.

• The blade has a notch or a chou near the handle, which serves
as a blood groove, a religious symbol, or a stopper for the index
finger. The notch also helps to balance the blade and prevent it
from slipping.
• The handle is typically made of wood, horn, or metal and has a
cylindrical shape that flares out at the end. The handle can
have a metal bolster and a pommel for added strength and
protection. The handle can be either full tang or rat-tail tang,
depending on the quality and durability of the knife.
• The sheath is usually made of leather and has a loop or a frog
for attaching it to a belt or a sash. The sheath can also have one
or two smaller knives called karda and chakmak, which are
used for utility and sharpening purposes.
 Materials Needed
• Plain carbon steel.
• Wooden handle material (hardwood used deodar)
• Brass or steel pins for securing the handle
• Hammer
• Steel Jack Plane
• Power tools (cut off saw)
• Safety equipment (gloves, safety glasses, apron)

STEPS FOR PREPARING KUKRI KNIFE

1. Design and Planning

According to the measurements we created a detailed

design of the Kukri knife, including the blade's curvature,
handle shape, and overall dimensions. Later, we marked
the dimensions on the workpiece.

2. Cutting the Blade Blank

First, we designed the tip of the kukri knife. We used a

cut-off saw to cut the workpiece into the desired shape
of the knife tip.
3. Heat Treatment
Later, we heat treated the blade in the furnace so that
we could hammer it to the desired shape. This step also
increased its durability and hardness. This step involves
heating the blade to a specific temperature till it
becomes red hot so that it becomes easy to bend it to
the desired shape.

4. Shaping the Blade

We used hammer to bend the workpiece to give the
blade's shape and create the characteristic curve of the
Kukri knife. Here, we again
used cut-off saw and angle grinder to give sharpness
and smooth finish to the blade to the blade.
5. Handle Preparation
To give the desired handle shape we marked
dimensions on the workpiece and using cut off saw we
cut the workpiece according to the dimensions.
6. Safety and Precautions
While working on the Kukri knife, we prioritized safety.
• Worked in a well-ventilated area
• Maintained a clean and organized workspace
• Used the right tools

Possible Defects
• Unfilled Section: This defect is primarily caused by poor
die design, inferior raw materials, improper forging
techniques, improper die layout, and poor heating.

• Scale Pits: A common type of forging defect caused by

improper surface cleaning of forged parts. When the die
is pressed against all impurities like dust on the surface,
the metal may develop minute cracks or holes.
• Cold Shut: They are seen as small cracks at the corners of
the workpiece. Sharp corners, poorly designed forging
die, and an excessive cooling process after forging are
some of the causes of these defects.
• Die Shift: These flaws may appear if the upper and lower
dies are not properly aligned. Incorrect measurements of
the workpiece are the root cause of these
misalignments.
• Improper Grain Growth: Improper metal flow during the
casting process can cause improper grain growth.
• Flakes: The rapid cooling of the forged parts results in
internal cracks which reduces the overall strength. These
defects occur when forging operations are performed at
a lower temperature than required.
• Incomplete Forging Penetration: This forging defect
appears when forging is done improperly. Light or strong
hammer blows result in incomplete forging.
• Internal Cracks: It is typically the result of secondary
tensile stresses induced during the forging procedure.
• Residual Stress: Residual stress is the result of improper
cooling of forged parts during the forging process which
leads to significant plastic deformation.