Metal Forging

History

Metal Forging is one of the oldest metal forming methods of human society, and powered forging dates back to the 12th century. Metal is formed (or shaped) by large, localized compressive forces, i.e., in the olden days metal was hit by a hammer by a blacksmith. Typical products on the market today that are manufactured using metal forging techniques include axles of vehicles, gears, mallet and axe heads, engine valves, bolts, screws, etc.

Usage of Forging

The advantage of forging over other manufacturing methods such as metal casting or machining is not evident from the surface finish, but lies in the internal chemistry of the metal material. As iron is heated, its molecules loosen the holding “force” and the metal becomes softer. This allows a blacksmith to effectively change the shape of the metal by hitting it. But, by doing, so, the grains of metal are compressed and the density of the material becomes higher at that point of impact. This results in a much stronger metal, as the grains become continuous over the shape of the product (Glenn, 63).

Casting, on the other hand, cools down without any force on it (or a very small force compared to a forging process) and the molecules are placed evenly throughout the material which gives good uniformity but ordinary structural strength. Today, the process of forging is automated by the usage of industrial presses or hammers that fire the impact compression necessary as a result of compressed air. Firstly, billets or ingots of raw material (usually iron or steel) are placed in a high-temperature furnace for heat-forging. Although metals can be forged cold (i.e., not heated to improve their malleability), it takes less energy to heat the metal and then forge it than to forge it cold. Forging cold metal also creates strain hardening in the material, which is artificial hardening of the material due to plastic deformation and may be undesirable if the product will need a secondary finishing technique such as machining (Nigel, 143).

Abilities needed to forge

Blade smiths have been around for centuries, providing knives and swords. They must work carefully with heat and metals and have the patience to shape and refine their blades into fine pieces of craftsmanship. Using these abilities, these artisans produce items of utility and beauty no matter what their purpose may be. A blade smith must be handy with a hammer and anvil for shaping a blade while it is hot and malleable. Forging determines the shape of the metal, so this skill is important for achieving the desired result. The blade smith must also understand that it is necessary to work both sides of the metal with an equal number of blows from the hammer and maintain a forging temperature of 1,400 to 1,800 degrees during this process.

Equipment needed for a hobbyist

There are various equipments that might needed by a hobbyist. It is used in several forms which will be discussed in the following paragraphs:

Roll Forging: where a round billet is ...