SHRI RAMDEOBABA KAMLA NEHRU ENGINEERING COLLEGE, NAGPUR

INDUSTRIAL ENGINEERING (WORKSHOP)

SMITHY SHOP
ST

(1

YEAR B.E.)

SMITHY SHOP
INTRODUCTION :The process of giving a desired shape to a metal piece by heating and hammering is known as forging. The metal piece is heated up to a desired temperature, known as forging temperature. The processes involved in forging are hammering, pressing, swaging, bending and flattening etc. Forging is widely done in ante 1 bicycle industries. It has the following advantages over the other machining processes : 1. It refines the structure of the metal. 2. It increases the strength. 3. It saves time, material and labour.

FORGING TOOLS AND EQUIPMENTS :The following tools and equipments are used in a smithy shop. 1. Furnace or hearth 2. Anvil 3. Hammers 4. Tongs 5. Chisels 6. Punches & Drifts 7. Ratters 8. Fullers 9. Swages 10. Swage block 11. Set hammers 12. Clamping devices

(1) FURNACE OR HEARTH

A Black smith uses a furnace for heating the metal pieces. Furnace consists of four legs, a cast iron or steel body, iron bottom, a chimney and a blower. i) HEARTH :- The iron bottom where fire is lightened is known as hearth. It is provided with fire brick lining. ii) TUYERE :- A pipe coming from the bottom or rear of the hearth is known as tuyere. It is used to supply the air at high pressure. iii) HOOD :- The upper part of the furnace is called hood. It is made up of mild steel sheet with fire bricks inside it. iv) CHIMNEY :- Chimney is fitted on the upper end of the hood. It is used for the purpose of easy escaping of exhaust gases and smoke. v) WATER TANK :- A small iron tank is attached with the hearth of the furnace. It is used for dipping purposes. ACCESSORIES FOR A FORGING FURNACE :i) SHOWEL :- It is used to place the coal into the furnace hearth. ii) BLOWER :- It is used to supply air at high pressure to the hearth. iii) POKER :- It is a bent rod used to strike the fire. Poker is made up of mild steel. iv) REGULATOR :- It is used to control the supply of air to the hearth. Air supply is controlled by increasing or decreasing the passage of air.

(2) ANVIL
A block on which forging work is done is known as anvil. It is made up of a cast iron, steel or wrought iron. It is available in many sizes and shapes. Common type of anvil used in forging shop has the following parts : a. Body b. Horn c. Chipping block d. Face e. Hardie hole f. Round hole g. Tail h. Stand The central part is known as body. The projected end is called horn. It is used for making circular jobs. A steel plate riveted on the body is called face. Most of the work is done on face. Chipping block is used for cutting purposes. Holes are used for chisels or punches. At the bottom four legs are attached.

(3) HAMMERS
Hammers are used as striking tools. These are classified as under : i) Hand hammer ii) Sledge hammer iii) Power hammer Hand hammer is light in weight used by the smith himself. Sledge hammer is heavier in weight and is used by the smiths helper. All the hammers are divided in to four parts namely peen, eye, cheeks and face. The weight of hand hammer varies from 1 kg to 2 kg and that of sledge hammer is 3 kg to 8 kg. Common types of hammers. When the quantity of jobs to be produced is more, power hammers are used. Commonly used hammers are spring hammers, pneumatic hammers, steam hammers and drop hammers. Power hammers are generally driven by electrical power. The job to be produced is placed on the anvil of the hammer. With the help of a lever the weight is allowed to fall on the job.

(4) TONGS
Tongs are used for holding and turning hot metal pieces. Depending upon their use, tongs are classified into many types. All types of tongs have similar construction except the mouth. A tong has two legs riveted, from a suitable place. These are made up of mild steel. Various types of tongs are used in forging shop.

(5) CHISELS
Chisels are used for cutting metal pieces in hot and cold state. Chisels are divided into following categories : a) Hot chisel b) Cold chisels Hot chisel is used to cut the metal in hot state and cold chisel to cut the metal in cold state. Main difference between these chisels is the cutting angle. In hot chisel the cutting angle is 300. But in case of cold chisel its value is 60 0.

(6) FLATTERS
As indicated by the name, flatters are used to flatten the work piece. It has a plane face joined with a straight shank. It is held in a thin wire. The material of the flatter is high carbon steel.

(7) FULLERS
Fullers are used for grooving and drawing. These are made in two pieces (lower and upper). Lower part is mounted on the anvil and the upper is held in hand from a wire handle. These are made from high carbon steel and medium carbon steel. These are used for hot work only.

(8) SWAGES
Swages are used for giving various shapes to the work pieces. These are made up of high carbon steel and are used in two pieces as in case of fullers.

(9) SWAGE BLOCK

It is a cast iron or cast steel rectangular block having a number of holes on it. Holes are made in different sizes and shapes. Its outer sides are also made in sectional forms to receive various types of jobs. It is always placed on a cast iron frame.

(10) CLAMPING VICE

Leg vice is only damping device used in smithy shop. It is mounted with the table or wooden base. It consists of two jaws, a spring and a leg. Hot work pieces are damped in it while working.

PRECAUTIONS WHILE USING FORGING TOOLS AND EQUIPMENTS :The following points must be kept in a mind while working with the forging tools : 1) Hearth should be lightened in proper way. 2) Hammering should not be done in lazy mood. 3) Heavy blows should not be given on the tail of the anvil. 4) Hammers should have proper handle length. 5) Length of the tong should be kept between 15 to 18. The tong should be kept cool while working with it. 6) Blunt chisels should not be used in the forging shop. 7) Mushroom should not be remain on the face of the flatter, punch or chisel. 8) Never use fullers and swages for cold metal. 9) While working on furnace, keep the fire small but deep. 10) Do not let fire burn hollow. 11) Keep the fire clear from clinkers, particular while welding. 12) Do not add fresh coke on the top of the fire, put it at the side and pull in later when required.

FORGING OPERATIONS :In forging shop, the following operations are used in common. 1. Drawing 2. Upsetting 3. Punching 4. Fullering 5. Bending 6. Forge welding

(1) DRAWING
Drawing is the process in which a red hot metal piece is beaten up by a hammer. The thickness or diameter is decreased but length increases. The hammering is done by placing the hot piece on the anvil.

(2) UPSETTING
It is the process in which the diameter of the hot work piece is increased and length is reduced. Hot metal piece is placed on the anvil in vertical position. It is struck with a hand hammer. The hot work piece is held in a long. Some times during upsetting, bending occurs on the job. In such cases first the job should be straightened and then upsetting should be continued.

(3) PUNCHING
Punching is the process in which a rough hole is made into the hot work piece. The job is heated to a desired temperature and then it is placed on the anvil. Punch is placed is placed on the hot metal piece. With the help of a sledge hammer, the punch is forced to pierce the metal up to half of the metal thickness. Then the punching is done from the second side by inverting the work piece. A rough hole is produced.

(4) FULLERING
Fullering process is done on an anvil. Lower part of the fuller set is kept in the hole of the anvil. Hot work piece is placed in the groove of the lower fuller. Upper fuller is placed on the job and hammering is done on the upper portion. Fullering is done for drawing and grooving.

(5) BENDING
The process of giving desired angles or curvature to hot pieces is known as bending. The process is done on the edge of the anvil or on chipping block. Circular shapes, eye bolts, hooks or any other type of bent shape can be prepared with this operation. The hammering is done on hot work piece with a hand hammer. Hot work piece is held in a tong.

(6) FORGE WELDING

The process of joining two metal pieces by heating and hammering is known as forge welding. The metal pieces to be welded are cleaned and heated in a furnace up to the welding temperature. Then both pieces are picked from the furnace with the help of the tongs. Work pieces are placed on each other and hammering is done on them. And both the pieces get welded. The following factors must be considered while welding. i) Metal pieces should be clean and free from any scale. ii) Pieces should be heated up to proper temperature. Some times flux is also added while welding process. There are three types of welded joint in common.

Shop :- SMITHY
Job No. :- 1 Aim :- To make a Semi circular hook by forging method. Material required :- M.S. rod 12 x 290mm length Tools required :- Smithy hearth, Ball pin hammer, Anvil, Round hollow tonge, Steel rule, Cold chisel, Outside caliper etc.

Date

Operation

Tools & Equipments

Specification
300 mm

1) Checked the given m.s. rod for dimension. Steel rule 2) Heating of the Job up to 7000c to 1300 0c. Smithy hearth

3) Setting down (square section) as per Anvil, Ball pin hammer, drawing. 4) Drawing down for change of circular dimension. 5) Marking &cutting of the rod. -----do------Cold chisel, Steel rule & Ball pin hammer 6) Bending of the rod as per drawing. Anvil, Hammer & Tonge Round hollow tonge

7) Measuring actual dimension as per Steel rule & Outside caliper drawing. 8) Write the roll number on plane paper & Gum stick on the Job.

Job completed & submitted on :GRADE:Signature of Instructor :-

Total time required :-

Signature of W.S. :-