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D
AKSHMI NARAIN COLLEGE OF TECHNOLOGY,BHOPAL

BLACKSMITHY

Black smithy or Forging is an oldest shaping process used for the producing small articles for which
accuracy in size is not so important. The parts are shaped by heating them in an open fire or hearth
by the blacksmith and shaping them through applying compressive forces using hammer.
Hand forging process is also known as black-smithy work which is commonly employed for
production of smallarticles using hammers on heated jobs. It is a manual controlled process even

though some machinery such as power hammers can also be sometimes used. Black-smithy is,

therefore, a process by which metal may be heated and shaped to its requirements by the use of
blacksmith tools either by hand or power hammer.

Applications of forging
Almost all metals and alloys can be forged. The low and medium carbon steels are readily
hot forged without difficulty, but the high-carbon and alloy steels are more difficult to forge and

require greater care.

COMMON HAND FORGING TOOLS

Tongs
The tongs are generally used for holding work while doing a forging operation. Various
kinds of tongs are shown in Figure.
a) Straight-lip fluted tongs are commonly used for holding square. circular and hexagonal bar stock.

b) Rivet or ring tongs are widely used for holding bolts, rivets and other work of circular section.

c) Flat tongs are used for mainly for holding work of rectangular section.
d) Gad tongs are used for holding general pick-up work, either straight or tapered.

Straight-lip fluted tongs Rivet or ring tongs

Flat tongs

Gad tongs Flat to ngs

Flatter
Flatter is shown in Fig. It is commonly used in forging shop to give smoothness and accuracy
to articles which have already been shaped by fullers and swages

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DEPARTMENT OF MECHANICAL ENGINEERING
 BS. E
LAKSHMINARAIN COLLEGE OF TECHNOLOGY, BHOPAL

Rivet header

Fuller

Punch

Swago
Hot chisel

Swage
Swage is used for forging work which has to be reduced or finished to round, squre or

hexagonal form. It is made with half grooves ofdimensions to suit the work being reduced. It

consists of two parts, the top part having a handle and the bottom part having a square shank which
fits in the hardie hole on the anvil face.

Fuller

Fuller is used in forging shop for necking down a forgeable job. It is made in top and bottom
tools as in the case of swages. Fuller is made in various shapes and sizes according to needs, the size

denoting the width of the fuller edge

Punch
Punch is used in forging shop for making holes in metal part when it is at forging heat.

Rivet header
Rivet header is used in forging shop for producing rivets heads on parts.
Chisels
Chisels are used for cutting metals and for nicking prior to breaking. They may be hot or cold

depending on whether the metal to be cut is hot or cold. A hot chisel generally used in forging shop is shown
in Fig.

tempered
necessary.
The main diference between
with an angle of about
The edge is made slightly
the

60 , two is in the edge. The edge of a cold

whilst the edge of a hot
rounded for better
chisel

cutting action.
is
chisel is hardened and
30° and the hardening is not

Hand hammers
There are two major kinds of hammersare used in hand forging:
a. The hand hammer used by the smith himself and

b. The sledge hammer used by the striker.

Hand hammers may further be classified as (a) ball peen hammer,(b) straight peen hammer,
and (c)cross peen hammer.
Sledge hammers may further be classified as (a) Double face hammer, (b) straight peen
hammer,and (c) cross peen hammer.
Hammer heads are made of cast steel and, their ends are hardened and tempered. The striking
face is made slightly convex. The weight of a hand hammer varies from about 0.5 to 2 kg whereas
to 10 kg.
the weight of sledge hammer varies from 4
a

DEPARTMENT OF MECHANICAL ENGINEERNG

 B.s.
LAKSHMI NARAIN COLLEGE OF TECHNOLOGY,
BHOPAL
Cross peen
Straight peen

Eye

Cross peen hammer

Straight peen hammer

Face

Ball peen hammer (a)Double face (b)Straight peen (c)Cross peen

Set hanmmer

A set hammer generally used in forging shop is shown in Fig. 14.9. It is used for finishing
corners in shouldered work where the flatter would be inconvenient. It is also used for drawing out
the gorging job.
Anvil
An anvil is a most commonly tool used in forging shop which is shown
in. It acts as a support
for blacksmith's work during hammering.The body of the anvil is made of mild steel
with a tool
steel face welded on the body, but the beak or horn used for bending curves is not steel faced.
The
round hole in the anvil called pritchel hole is generally used for bending rods of small diameter, and
as a die for hot punching operations. The square or hardie hole is used for holding square shanks of

various fittings. Anvils in forging shop may vary up to about 100 to 150 kg and they should
always
stand with the top face about 0.75 mt. from the floor. This height
may be attained by resting the anvil
on a wooden or cast iron base in the forging shop.

rHard e hole (square)

Chipping blck (rectangular)

Horn or -Pritchel hole (circulari

beak Tail
O
00
-Bodybnkod Jo
Base (W.)

Slots
Swage block

Swage block

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DEPARTMENT OF MECHANICAL ENGINEERING
 B.s.4
LAKSHMI NARAIN COLLEGE OF TECHNOLOGY,BHOPAL

Swage block generally used in forging shop is shown in figure. It is mainly used for heading,
bending, squaring, sizing, and foming operations on forging jobs. It is 0.25 mt. or even more wide.
It may be used either flat or edgewise in its stand.

FORGING OPERATIONS:
The followingare the basic operationsthat may be performed by hand forging:
1. Drawing-down:
Drawing is the process of stretching the stock while reducing its cross-section locally.

Forging the tapered end ofa cold is an example of drawing operation.

2. Upsetting:
It is a process of increasing the area of cross-section of a metal piece locally, with a
corresponding reduction in length.
3. Fullering:
Fullers are used for necking down a piece of work, the reduction often serving as the starting

point for drawing. Fullers are made of high carbon steel in two parts, called the top and bottom
fullers. The bottom tool fits in the hardie hole of the anvil. Fuller size denotes the width of the fuller

edge.
4. Flattering:

Flatters are the tools that are made with a perfectly flat face of about 7.5 cm square. These
are used for finishing flat surfaces. A flatter of small size is known as set-hammer and is used for
finishing near corners and in confined spaces.
5. Swaging:
Swages like fullers are also made of high carbon steel and are made in two parts called the
top and swages. These are used to reduce and finish to round, square or hexagonal forms. For this,

the swages are made with half grooves of dimensions to suit the work.
6. Bending:
Bending of bars, flats, etc., is done to produce different types of bent shapes such as angles,
ovals, circles etc. Sharp bends as well as round bends may be made on the anvil, by choosing the
appropriate place on it for the purpose.

7. Twisting:
It is also one form of bending. Sometimes, it is done to increase the rigidity of the work
piece. Small piece may be twisted by heating and clamping a pair of tongs on each end of the section
to be twisted and applying a turning moment.
8. Cutting (Hotand Cold Chisels):
Chisels are used to cut metals, either in hot or cold state. These chisels are made of tool steel.

hardened and tempered.

SAFE PRACTICES:
1.Hold the hot work downwards close to the ground, while transferring from the hearth to anvil, to
minimize danger of burns; resulting from accidental collisions with others.

2. Use correct size and type of tongs to fit the work. These should hold the work securely to prevent
its bouncing out of control from repeated hammer blows.

DEPARTMENT OF MECHANICAL ENGINEERING 10

 KSHMINARAIN COLLEGE OF TECHNOLOGY, BHOPAL
Care should be exercised in the use of the hammer. The minimum force only should be used and
e flat face should strike squarely on the work; as the edge of the hammer will produce heavy
uising on hot metal.
Water face shield when hammering hot metal.
Wear gloves when handling hot metal.
Wear steel-toed shoes.
Ensure that hammers are fitted with tight and wedged handles.

EXPERIMENT NO.
AIM:
To prepare a chisel of mild steel.

APPARATUSES / TOOLS USED:

Furnace
2 Coal
3. Anvil
4. Swage block
5 Hammers :Hand hammer,sledge hammer etc.
6 Tongs
7. Chisels

RAW MATERIAL:
Mild steel work piece of 12 mm diameter, 100mm long.

PROCEDURE:
1 Ignite the furnace.
the furnace heat one end of the work
adequate temperature has been reached
in
2. When
piece in the furnace.
it out of the furnace with the help of tongs.
3 When end becomes red hot, take

4 Put the end of the work piece onto the anvil, holding it with the tong.
shape
piece repeatedly till the rough chisel like
is
5 Hammer red hot end of the work
formed.
the furnace, when end becomesred hot, take it
6. If required, put the work piece again in

out.
that a finished chisel is formed.
Again hammer the end of the work piece such
8. Put the other end of the work piece in the furnace, when end becomes red hot, take it

out.

the end of the work piece such that a square head is formed.
9. Hammer
10. Allow the work piece to cool down.

RESULT:
of given dimensions is made successfully.
The smithy job (chisel of mild steel)

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DEPARTMENT OF MECHANICAL ENGINEERING
 B.S.(e
NARAIN COLLEGE OF TECHNOLOGY, BHOPAL
LAKSHMI
PRECAUTIONS:
While hammering the work piece, hold it firmly with the help of tong.
1
Do not wear loose clothes while hammering.

COMMENT:
The surfacefinish and dimensional accuracies achievedon the smithy job are because
of the following:
1. Under/over heating ofthework pieces.
2. Characteristics of the work piece material.
3. Human errors (Fatigue, Less knowledge about tools & procedures).

ndol

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DEPARTMENT OF MECHANICAL ENGINEERING