. .· . ..

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5. Smithing and Forging 97
· 5.1 Introduction 97
5.2 Forging Materials 97
5.3 Tools and Equipment Used
in Forging 97
5.4 Forging Temperature of ·
Different Materials 103
5.5 Forging Operations 103
5.6 Power Hammer and Presses 107
5.7 Heat Treatment 107
5.8 Questions 108
 ·1
I

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Safety shou}cf.be\1h'ie\ier'y:·/8embnsirator 's
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audlenc.:4, ·but for: yourself as w'ell ·:. ' . ·. ;•,:'!-'··::'0_;-.--:'."f'. ,;:. j,j .
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1) Work slow and _alw~ys .be: a\vnre 9f your audience . .
2) Sebarme tlie· aucti~flce ·from your fo ,g; ng_:area .as mu~h as
possible .. Use a_:.f~p_e.·barrier. _display table·,. or. som~thing··.to ·,' .
makc·:a :boun~_aryl f~ople tend' to mo\;e ~ci6ser. and .: closeii~ ._·.
:rhey' .get :-i1iyo1y:eo)'r~· watching: Most ctemo'nstrators ·r.ri;- .:to . ·: ·
keep at leasi.-_ten feet Ji stance between th~: forging area ·and -.;..
tile audici1cc. · ,
!
3)
v Always wear your snl'cry glasses, ancl if poss ible have your
~: viewers wear them al.~o.

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!.
' 4)
Preferably' keepJ~l!f ,aud iei,ce j II nr OCyo_uins te'a<l on
rhe sides. , . ·· ·/--- ;,:., >. . · . . . : .. .- . , • ·
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5)
Wear .an apron·~ J,iot .only is it nostalgic,
injury .
bur it could prevem
6) ·Tc1lk about safety and warn of spar.ks. sharp edges c1•1d bot
items. No matter· how ~incerc rhey m;iy be, don't let the
~
viewers pick .up iools or pieces you are working on.
'
7) Ket:p all hot pieces (cu t-uff.s, ere .) under the forge and away
rrnm people. It rn2y be best to quench c1II pieces w be on
tile sale side.
8) Have a first aiu kit handy. You never know when you rrugh1
bu rn or cut yourself.
. :.
9) Forge welding is always fascinating co wa tc~, but· ~an be
very d angcious.
•. ·It 1-5 · best
· not to forge weld if possible
, .·
l 0) Wlten using a hc1 rdy , ne ve r cut completely through stock.
Use your tongs to brc:i k rh c end off.

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 SMllHING AND FORGING

5.1 Introduction
l pressure to give the desired ahape
'Ibe p_rocess of he~ti~g the material u~ to _its plastic state and then applying externa
or voids present in the material and
and size to_matenal is ~own ~ srmthymg or forging . It reduces any cavities
with the grains and they get brok.en
thus make it dense. The impunties present in the material, also gets elongated
impurities and improve the mechnical
and dispersed througho~t ~e material. It will reduce the harmful effect of the
strength. In many cases 1t 1s more economical process than any other process.
be heated in open fire or hearth.
Smithying is the process of handling relatively small jobs only such as those can
Forging is the process of production
The operation is carried out by using of hand hammers or small power hammers.
forging is done is tenned as forge.
of those jobs which must be heated in a closed furnace. The part of the job where
es, presses etc.
The work is generally perfonned by means of heavy hammers, forging machin

5.2 Forging Materials

In common practice, any metal or alloy which can be deformed in
plastic stage through heating can be forged.
be forgeable or in other words,
Forgeability is the ability of the material to get forge. The ductile material should
increases with temperature up to a
ductility is directly related to its forgeable quality of the material. Forgeability
p<?int at which a second phase appears.
!!um}nium alloys and magnesium
· L._farbon steels, all,QY_steels, wrought iron, copper-l;LasulloYJ.Mkel:.based alloys;J
but the high-carbon and alloy steels
alloys, etc. are forged easily. The low and medium carbon steels are forged easily,
are more difficult and require greater care to forge.

5.3 Tools and Equipment Used In Forging

r of tools and appliances are used
To perform the different type of operations in smithing and forging shop, a numbe
as per their requirements and applications are described.

Anvil The body of the anvil is made of

Toe anvil is used as a supporting device for blacksmiths work when hammering.
to protect the anvil shape from bea~
l!!i]d steel or wroueht iron. Tool steel plate is welded on th~ top of th~ body,
d shapes. The back part of the anvil
blows of hammering etc. The beak or porn is used for bending or fomun_l:urve
is known as tail and carries pritchel and hardie bole. Pritchel hole is of round
shape is used for bending rods of small
for holding square shanks etc. The
diameter and as a die for bot punching. Hardie bole is of square shape and is used
weight is varying from 100 to 150
anvil is r~sting on cast iron or hard-wooden base for attaining the height. Anvils

--
---
kg and height should stand about 0.75 m from the floor.
 Face Hardie Hole
Chipping Block

\
Pritchl Hole
Hom

Anvil

fig.5.1 Anvil ·

~ g e Block ·
It is also a supporting device which have a number f differ~nt shapes and sizes
o! slots an~ ho1~s ~ and forming operations. along its four side
faces. It is used mainly for squaring, bending, punc
hing, heading, s1Z1ng

Q3 ga~g
lBQ3 Q
ooo
Swage Block
Fig. 5.2 Swage Block

Tongs
It is a holding device used to support and grip the job .
while some operation is carried out. It is made of
two pieces, and are riveted together to form a hinge. mild steel lll
It is specified by its shape of mouth and length.
On the basis of applications, it may be classified as:
(a) Flat Tong: It is used for supporting and gripping
of small flat objects.
r
Flat mouth tong: It is used for supportin
(b) g comparatively 1
tong. onger fl at Jobs.
• .
It ts also known as two side supported
(c) Square hollow ~'ong: It is used for supporting and . . .
Chisel Tong: It 1s used for unsymmetri al . b gnpping of triangular and square jobs
(d) ..., c JO s etc and als0 kn - .
(e)
Single supported tong: It is used for supportin fl · . . own as belt tong.
Round hollow Tong: It is used for supportin g at ~ ~ havmg more width etc.
1
{f)
pjnear Tong: It is used for supporting and ~ ~d gnppmg-of r~und ~bjects in parallel direction.
(g)
Pickup Tong: It is used for supporting andgn~p~g of round Objects ID perpendicular directions.
(h) . gnppmg of very small jobs.

:
: ~=a=t-'Ii_o:n:g:::::== ===::J
~
Flat mouth tong

Square hollow Tong

Chisel Tong

Single supported tong

~o~-=======:::::i
Round hollow Tong

PinearTong

Pickup Tong
-- .......
Tongs
Fig. 5.3 Tongs

Hammers
Hammers are used to strike a tool or a job. All hammers consist of the following parts namely peen, head, eye and
face. The eye is nonnally made oval or elliptical in shape and it accommodates the handle or shaft. They are made
of various sizes (weights) and shapes to suit various purposes (hammer blow and work metal). Depending upon the
nature of work, hammers can be categorized as power hammer and hand hammer. Hand hammers are designed in

L '
 . jJnilar shape commonly having dift
. p wer hammers are made~ used
'ff nt matenals, o 1 d alloy stee
different size and shape of,di ere ally high carbon stee an
:e after
hardening and temperinercnt
gfor
capacities as per requirement· Gener
hard face hammer.

Wedge

striking Face

Fig. 5.4 Ball peen Hammer

According to shapes, hammers are classified as:

Ball Peen Cross Peen Straight Peen Sludge

Hammer Hammer Hammer Hammer

Fig. 5.5 Hammers

Ball Peen Hammer: The peen has a round at one end and straight face at other end. It is used for riveting and
chipping, etc. These are available from 100 to 900 grams. _iijj. -
----=---
Cross Peen Hammer: It consists a cross peen at one end and straight face at other end and its peen is perpendicular
the handle. It is used for hammering, stretching and bending e~c. These are available from 200 to 900 grams.
Straight Peen Hammer: It consists a cross peen at one end and straight face at other end and its peen is parallel the
handle. It is used for stretchin,& and peening etc. These are available from 100 to 900 grams.
Sledge Hammer: It has double striking faces at both ends. It may be square or hexag2!1& etc. It is generally used
for heavy work in black-smithy. Two operators are required for workingwrtb-this hammer. Generally it is available
from 2 kg to 10 kg.
~

Power hammers: Some heavy hammers are operated by power other than manual power, are come under this
category. These are used for heavy blow such as Pneumatic hammer, spring hammer, steam hammer and drop
hammer or drop stamp etc.

Chisels
It is ~ost widely used for cutting purpose. The selection of chisel depends upon the nature of work and these are
classified as:
 Wooden Handle

Steel Wire _ __.

r11111i-- -1-- - Cutting Angle
Clamp

Cold Chisel
Hot Chisel

Fig. 5.6 Chisel

(a) Hot ~bisel: This chisel is _used to cut the metal in plastic stage, there is no need
of hardenin g it. It is made of
medium carbon steel or high carbon steel and its cutting angle is kept about 30°. Hot chisel
is used to cut the
metal in plastic stage, there is no need of hardening it. Generally wooden handle is fitted in
it.
(b) Cold Chisel: It is similar to hot chisel but its length is generally kept more than
bot chisel. It is made of high
carbon steel and its cutting angle is usually kept about 60°. It is used to cut the metal in cold
stage, therefore it
should be well hardened and tempered. It is specified by its cutting width and length. It is
available with and
without handle in market.

Hardie
It is provided a square shank, which help it to fix into bardic hole in anvil. During cutting
or shearing operations,
chisels are used in conjunction with this bottom cutting tool. It is made by high carbon steel
and its cutting angle is
kept about 45°.

Fullers
Fullers are used for necking down or reducing the cross-section o.f.igb. They are made in pairs, top
and bottom tools.
Toe bottom part of fuller is fl~ bardic bol~ of anvil with i~square shank. Fullers are available in va~ous shapes and
sizes according to needs. The size of fuller is specified by the width of fuller edge. These are made
of high carbon steel.
Cutting Edge ----1~/iiilil!~" Roded handle

. - - - Shank
- Bonom

Fig. 5.7 Hardie Fig. &.8 fullers

..I
 b ttoro part of swage is fitted in hardie h
Swage . d bottom swages. The o .· fuller carries a wooden handle A~_e 1
Just like fuller these are also made that is top an The top part like . h · · "lCf
of anvil. They, are made by ~h carbon ste: l (Fig~e ~~iength of circular rod in crrcular s ape, types of operation
forging, finishing circular shape of job or for mcreasmg -
are performed by using swage.

Roded handle

Bottom

Fig. 5.9 Swages Set

Flatters
It is also made of high carbon steel. It has a flat square shape bottom and used for ~ g
surface more smoolifarurflat, whic h- have already been shaped by fullers and swages. It IS
made of high carbon steel with well hardened.

Punch and Drift Fig. 5.10 Flatter

Punch is a tool used for making holes in a job which is at red hot condition. It is available
in various size and shape i.e. round, elliptical, square and rectangular etc. The drift is similar in shape but it is more
precise. It is used after punching in a job to expand or open for accurate dimensions of hole. Drift is also a large sized

-
punch. These tools are made of high carbon steel.

Set Hammer
' -

It is similar to flatter and is used for finishing comers and shouldered work where the use of flatter is inconvenient. It
is made of high carbon steel.

Punch [)rift

Fig. 5.12 Set Hammer

Fig. 5.11 Punch and Drift
 5, forging Temperature of Different MaterialI
~
' temperature of mainly used materials arc as:
wrought Iron sso • 1300°c
Mi)d Steel 750. 1300°C
Medium Carbon Steel 750 . 1250oc
High Carbon Steel 750. 1150°C
stainless Steel 950 - 1200°C
erass, Copper, Bronze 550 • 900°C
Aluminium, Magnesium 300 • 850°C

s.5 Forging Operations

A[l1llllber of operations are used in smithying and forging work for changing the shape of given raw rnatr:rw to the
finished or required shape. They are listed and described below:
1. Upsetting. 2. Drawing down. 3. Setting down.
4. Bending. 5. Cutting. 6. Punching and Drifting
7. Fullering 8. Welding.

Upl8tting
Jt is the process of increasing the thickness or cross-section of the metal at the expense of its length. It is al~ known
as jumping. The metal is heated upto its plastic st.ate and then applying the pressure with the help of hammer after
supporting the metal on hard surface i.e. anvil etc. The metal tends to increase in its dimensions at 90° to the direction
of application of force with a corresponding reduction in its dimensions parallel to the line of action of applied force.

(a) (b) (C) (d)

Ag. 5.13 Upsetting

The upsetting operation is done as: . b bea hammer blows 00 1 unifonnly tattd metal.
(a) upsetting is to be done throughout the en~ ~ ~ ce?ae, part -which is no( up,ct. cooled by qUtochina a.n
(b) upsetting is done at both ends of the wort:piece
water. tal
(c) upsetting takes place at the lower part of the me ·
(cf) upsetting takes place at the middle part of the meta.I.

Drawing Down . , creased 11 the upen1t of its thickness or ai dlb or both. It is also known
In this process, the length of the metal 15 m pro«U thal of upsenJng.
10
as swaging. In other words, it is exactly the reverse
 . ' I

· . .nal metal, (b) metal after hammering With

• h n in figures, (a) ongi a
The stages of drawing down operation are s ow ~ . g with the flatter.
straight peen hammer or with top fuller, and (c) finished orgm

CL--_____j
(a)

(b)

(c)

Fig. 5.14 Drawing Down

Setting Down
Setting down is a localized drawing-down operation. It is used to change the roundness of a comer for making square,
by using set hammer. Fig.(a) illustrate the operaion of local thining down by using set hammer. Nonnally, the length
of any metal is increased at the cost of its width. Fig. (b) shows the process of setting down both faces of a bar by
using a top and bottom fuller and Fig. (c) illustrate the use of flatter close to a shoulder.

- .
(a)

0
0

(b) (c)
Fig. 5.15 Setting Down

Bending
~ending ~s an important operation in forging and may be classified as curvilinear e t,ent
mto required shape by using bending operation. Bending is done over the an ·1 f or angular. ~ars and flats ar ial
forms such as the swage block edges etc D . b di . vi ace, over the anvil horn or over spec
' · unng en ng operation, the layers of metal on the inside are shortened
 S,,,,lthing and Forging

.
and on the outside are stretched. This is caused bYbu1gmg
· · at th · ·d
angular bending is reqwred, an additional metal is worked out eatms1 e, and radius on the outside of the \.'- d If an
t ak th th l ucn .
metal will go o m e up e comer. After bending, flatter 1s. e p ace where the bend occurs This adcliti'onal
• 'd d Th used top th . ·
for the ms1 e e ge. e stages of bending over the anvil ho . repare e outside edge and set hammer is used
m by usmg hammering are shown in figures.

Curvilinear

Angular

Fig. 5.16 Bending operation

Cutting
ely. Cutting
Cutting operation is done by using hot and cold types of chisel in hot and cold condition respectiv
extra metal from the job
operation is used to cut a long metal piece into several pieces of required length or to remove
metal is heated in
before finishing it. Cold cutting is preferred for cutting thin flat or round sections. For hot cutting,
When chisels are used
a black smith's hearth or furnace to a light cherry red heat, from 850°C to 950°C temperature.
for cutting, the hammer blows are directed on to the chisel head, which must be slightly rounded.

Punching and Drifting

of hammer
In this process, holes of different size and shape are produced by using punch over hot metal with a blow
is placed on
etc. The holes made by punching are finished by using drift in it with proper blow of hammer. The metal
a punch in hot
the pritchel hole of the anvil or over a correct hole of swages block or over a cylindrical die, and then
condition is used for producing the hole. External pressure on punch is given with a blow of hammer.
Workshop Manual

2 3
1
Fig. 5.17 Punching Driftin g

Fullering
In this process the length of work piece is increased at the cost of its width. . .
It 1s also known as drawmg. Fuller set
is used in this 'process. Hot metal is placed over bottom set of fuller or any
hard surface, and blow of hammer is
provided directly on metal or over the top set of fuller.

Welding
Welding is an important operation performed by smith. In this operation,
two pieces of same metal are heated and
joined together with external pressure, so that they may act as a single one. The
metal pieces are heated in the smith's
hearth up to a welding temperature and then withdrawn from the furnace. These
metal pieces are joined together by
the application of external pressure through hammering. The metal which easily
welded is pasty over a wide range of
temperature, and wrought iron and mild steel have some advantages over other
metals.Flux is used for protection of
heated metal from oxidation. Commonly used fluxes in forge welding are: sand
with wrought iron and borax powder
with mild steel etc. For a sound welded joint, surfaces in contact should be clean
and free from scale, ash or dirt, their
presence will lead to the failure of the joint.
The different joints are in use in forge welding are:
(a) Butt weld: In this welding joint, metal pieces are jointed together end to
end. The weld, between the ends makes
right angles to the length of the piece. But this joint is difficult to make by hand
operation, due to not applying
pressure in proper direction.

Before After

Fig. 5.18 ButtWeld

(b) ~a? or s~arf_weld:_In ~s wel~g .jo~t, e~ds are prepared and welded one
upon the other. The welding joint
ts m the mclined direction. This JOtnt 1s easier to make by hand hammering
direction. , due to ap 1 · · oper
p ymg pressure m pr

.....--~
Before
-....... z
After

Fig. 5.19 Lap weld

(c) T or jump wel~: In this welding joint, one piece is placed at th
the fonn of an mverted T. e centre of another at right angle to each other in

J
Before After

Fig. 5.20 T-Weld

(ti) Split or fork or splice or V weld· In this weldi · ·

respectively. This joint is most se~ured form of ng Jomt, _ends ~e first br?ught to th~ sha~ of fork and tongue
of 'V'. This joint may be all d . . ~eld and is particularly suitable for thick pieces for the formation
c e strongest Jomt m forge welding.

>
Before After

Fig. 5.21 V-Weld

5.6 Power Hammer and Presses

Large machine part~ c~ot be forged b_y hand, the light blow of a hand·or sledge hammer cannot produce a great
degr~e of deformation ~ the metal bemg forged. The hand forging is a lengthy process and requires repeated
heatmg of the metal. This led to the use of power hammers and presses in forging. Machines which work on
forgings by blow are call~ hammers, while those working by pressure are called presses.

Power Hammer
The general principle of operation for all power hammers are common, a falling weight striking the blow, with the
entire energy being absorbed by the work. If further blows are needed, the striking weight is raised for the subsequent
blow. The hammer will provide the higher intensity of blow, if it fall at a greater height. For some hammers, the
striking velocity of the hammer is increased by mechanical means. The capacity of a hammer is determined by the
weight of the falling parts.
During forging operation, rigid support provided to the hammer is called anvil block. The foundation of
the anvil block built separately from the frame; so that the foundation will provide cushioning to the hammer
blows and not transmitted to the frames. The heavy falling part of the hammer is called the ram. The ram and
the anvil block have one die and called upper and lower dies respectively for squeezing the metal to be forged.
The working surfaces of the upper and lower dies are flat and horizontal in smith forging.
Generally, different type of power hammers are widely used in forging work and these are (a) pneumatic power
hammer, (b) steam or air power hammer, and (c) spring power hammer

5.7 Heat Treatment

Heat treatment is the operation of heating and cooling of metal or an alloy in a controlled atmosphere in the solid
state to produce certain desired properties. This process consists heating of metal to the predetermined temperature;
soaking of the metal at that temperature until the whole structure becomes uniform throughout the mass; and cooling
Workshop Manual

within the metal as per requirement.

nnation of desirable strUcture
of metal at predetermined rate to cause the fo .
The objectives of heat treatment are as:
(a) To relieve internal stresses
(b) To change the grain size
(c) To improve machinability .
(d) To increase the resistance to heat an? corroSio_n
(e) To change the electrical and magnetic properties
(f) To change the chemical compositio_n . 'li hardness, toughness, etc.
(g) To improve the mechanical properties 1.e. strength, ducU ty,
The various heat treatment processes are as follows:

Annealing . .. · ture and then cool it slowly. The purpose of

Annealing is the process of heating the matenal u~to c~ttcal _tem~e::mal stresses; refine grain size; softening the
annealing is to improve one or more of the properties like reheve m
metal; and improve machinability.

Nonnalizing
Normalizing is the process of heating the material at a temperature about 50oc _a.bov~ the critical temperatu
. t al
re t
or a
• • . . •
considerable penod and then allow 1t to cool m the arr. The purpose Of nonnalizmg 1sdtod remove
til't
m em stresses·
'
refine the steel structure; and improve the mechanical properties like tensHe strength an uc 1 Y·

Hardening ..
Hardening is the process of heating the meterial at a temperature about 30° to S0°C above the cnt:J.cal te~perature
for a considerable period and then cooling it suddenly in a liquid (water, oil or molten salt bath). This type of
sudden cooling is known as quenching. The operation of hardening is applied to all cutting tools and some important
machine parts. The purposes of hardening is to improve toughness, strength, ductility and elasticity properties; and
to develop high hardness to resist wear and to enable it to cut other metals.

Tempering
Tempering is the process of heating the hardened material at a suitable temperature (tempering temperature) below
the lower critical temperature and then cool it slowly in air. The purpose of tempering is to reduce internal stresses
produced during previous heating; increase the ductility of metal; and improve the toughness, make the metal shock
resistance.

Case Hardening
Case h~dening is the process of heating the material to red hot condition and then force the carbon contents into its
surface structure so that a certain depth along its surface becomes rich in carbon, then it is hardened as usual. This
process is also known as carburising . It is mainly employed for mild steel and wrought iron specially for the metal
containing low carbon contents. Alloy steel are usually quenched in oil and carbon steel in water. This treatment will
produce a hard fine grained case, while the core of the structure will retain the properties of low carbon steel.

5.8 Questions
1. State the ~ifference between 'smithing' and 'forging '. List the advantage and disadvantage of each.
2. Define with neat ~ketch open hearth coal fired furnace along with its working principle.
3. Define fuel used m various furnaces in smithy shop.
4. Explain with neat sketch, with specification and classification if any:
(a) Anvil (b) Swage black
(c) Leg vice
 sxplain with s~etchedan~ clas~thification of tongs used in smithy shop
5. l,ist any ten too1s us m ~Illl y shop. . ·
6. Nallle the common matenals used fot forging. Give the correct fo .
7· forgivable metal~. rgmg temperature of some of the common
State which one 1s forgeable metal and which one is not.
8. n,,ccribe the three types of drop hammer forging machin ·
9 v.,., .J:"' b es.
_~pl~ ~e Wllerence etween hot c~sel and cold chisel.
10 c..pJaUl dilferent types of hammers with specification and cl 'fi .
11, pi' "' • ass1 cation
List the 1orgmg temperature of following metals ·
12
· (a) Mild steel (b) Wrought·
. b. f iron
pjscrlbe 10 ne
13. . .
(a) Jumpmg or upsetting (b) Bending
(ti) Drifting and punching . .,..{e) Swauing {c) DraFulle~gd
· di" t · · 0
• (J) wmg own
14_De~g u~ren_ ope~ations earned tut in smith shop.
15, £xpl~ welding m Slllltb~, along with different types of welding joints used in smithy shop.
16. £xplam advantage of forgmg over other manufacturing processes.
17. Explain difference between fuller and flat.
l8. l)escribe press forging. How does it differ from drop forging?
l9. ~at is the difference between the hammer and press forging?
20. State ~e advantages of both m~hanical and hydraulic presses for press-forging applications.
21. Explam the advantages of forgmg. What is the role of temperature control in smithy process?
22. How many types of tongs are used in Smithy shop? Make neat sketch of any two of them.
23. Explain the applications of following in brief
(a) Belt tong (b) Square hollow tong
(c) Pickup tong (d) Flat tong
24. Explain various types of hammers used in smithy shop. How will you specify a hammer?
25. Differentiate between the applications of cold chisel and hot chisel.
26. What is difference between Gouge and chisel?
27. List the tools required for making a nail in smithy shop. Explain the process involved in making nail from a
square mild steel bar.
28. ·Differentiate between close hearth and open hearth furnace.
29. Make a short note on
(a) Flatter (b) Set hammer (c) Straight peen hammer
(cl) Ball pein hammer (e) Sludge hammer
30. What is the importance of blower in a smithy forge? How much air pressure should send in a smithy forge?
31. Explain various kinds of coal. What type of coal is most preferred in smithy shop for mild steel job making and
why?
32. Explain the characteristics of good fuel. List forging temperature for the following metals
(a) Mild steel (b) High carbon steel
(c) Brass (d) Stainless steel
33. What do you understand by temperature measurement in a smithy shop? How many methods can be employed
for various temperature measurements in smithy shop?
34. Explain the term 'forge welding'. How can you classify the forge welding?
35. Compare between a forged part and a cast part in relation to mechanical properties.
36. \yhat are the common forging defects, and what are they due to.
37. Why heat treabnent is necessary for forging?
 . j~!liJllRWP P!

SM IT HY
EXERCISES

12
 1!.~AKING A_: ROUN~'.t,_RqD·INTO SQUARE !:!.1::.~D· BO~ T _ , ·. ·•
• I
I

l)l{i\ WING :

',,
t

/
, ..e;.
.
I
0 IVJ = V2 + V3 i
..;

YI = .'.: (10) 2 Ir
4
V2 = 102 X 8

\I J =~(10)2 x 50
4
v· 1
=V 2 +V 3

78 .54></r :' = 800 + 3927 0

V)

Ir = 60

I
!
l· .

* All dimensions are in mm

* Not to, scale

13 : ~

•
IW C

-
lJ it: \ W IN G :

/ _,,, I
.
., .
t
,,.

/
/ /

\ ......./ I
.!

i Ii
lan60v = -
5
h · '= 8.66

Hexagon area = 6><Trianglc ~rea

I
' l
= 6 x (10 )(8'.66 J =
260
2
== Arca x Th ickness
head (V 11 )
Volume of hexagonal boll
= 260><9 = 2340 ( ·:I =:
0.9u = 0.9)
-
'I
V ,,, = .'..._, 10 2 Y5Q = J 927
,1

;-r 1
;/
--~ · I O· x/, = 78 5•1 1
Vo lum e of raw malen al
V . = VII + V Il l
I

78.54 x /, =2340.,.392 7
I, '8 0 (apprux )

* All dimens ions ar e in mm

* Not. lO scale
II
/./
 ~:,~KIN,;;\\wli""t>lioSilwo,Hex,GoN1"'"'1il''-i%rJIJ
D\TE .

«m
To m•k• • M"goNI headed 0011 of me 10><9 mm on on, ,M o( 1r,
rvur>.l rod . (L,·n; ,h of the rod·10 be made;, 50mm)

Mat eri;I supplied'

M.S . Round rod of diameter 10mm a11d ltng,h 10 be c,lcul, ted (r,f,r
,·,lc'lll•tiun) - -.

Tool s required:
I. l!lac<smith furl\Ke l Toni> 3 Anvi l
~- Swage block l Sl ed;e ~ Fla,cm

Scqucnccofop•rotion1 :
I. Heaiins 2 Ftmenmi
3 Formmg O<xo:1on.,I >h•pe 4 Chock ing 5 Coolin1

Working step•
f it11 len~1ho/1hc1 ivonwur, r:c,·e ""lculated >n<l u ,~ ·,;.1,md
lor opcr, 11on
Using1oni1 , 1hoendof,he worl:p1ecci1
Nrnaco1oou11nior1"e1he1empt,a1cte
Now1heworke1cce,s.,konfrom1hcforn1cc,ndke?L10tC.ehole
of1hoon•ilforfu"horpro<0,11n,

The l11mmenn11 P'"'"" """''" oui IO 0,:1cn tli, 00< end of

,l10workp,ece

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l>< •ded:,r,

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