FACULTY OF ENGINEERING

Prof. Dr. Abdel-Aziz Hegazy

Prof. Dr. Mohamed A. Rady
Asst. Prof. Sherif A. Elatriby
Asst. Prof. Mohamed A. Bhlol
Asst. Prof. Hosam ElRakayby
Asst. Prof. Nariman Ezzat

Student Name Date

Section No. Marks

Workshop No. 7 Forging Workshop

Contents
Topic Page
1. Introduction 27
2. Forging Operations 27
3. Tools and Equipments 27
4. Laboratory Training 27
5. Review Questions 27
6. Workshop Glossary 27
7. References 27

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 Workshop No. 7 Forging Workshop

Workshop Objectives
After studying this workshop, you should be able to
 Know the main concept of forging process.
 Know different forging process, such as, hand forging and machine forging.
 Know about different tools used in manual forging.

1. Introduction

Forging is about the plastic deformation of metals at high temperatures into the required
shapes and sizes using compressive forces applied through forging dies by a hammer, press or
any other means. Forging process may be broadly classified in to two:
- Hand forging
- Machine forging

Hand forging involves the shaping of metal with hand tools by heating them in an open fire.
Accuracy depends up on the skill of the blacksmith. It is used mainly for the repair of
maintenance work and in the production of small articles and tools. Machine forging is
employed for the production of machine and large size forging. In machine forging the
forging operation are done with the help of power operated hammers and presses.

2. Forging Operations
Forging operations can be as following:
Drawing down or swaging: In this operation, the cross section of the metal is reduced and
the length is increased.
Setting down: This operation is for reducing the thickness of the work piece in a small area.
Bending: Bending is an operation by which the metal pieces may be bent to form various
shapes without damage to its structure.
Welding: It is the process of joining together two pieces of metal after they have been raised
to correct welding temperature and then applying external pressure.
Cutting: Cutting the metal in the hot or cold stage done by means of hot or cold chisel.
Punching and drifting: It is the process of producing hole by using a hot punch over the
hole of the anvil or over a cylindrical die.

3. Tools and Equipment (Fig. 7.1)

a- Forge or Hearth: it is used for heating the work piece in hand forging. It consists of a
hearth for holding combustible coke, a tuyere for leading forced air in the hearth, a
blower for supplying air under slight pressure and a properly designed chimney for
carrying away the smoke and gases produced by the combustion. Generally, a small
water tank is also provided along with it for quenching purposes.
b- Anvil: Anvil is a supporting tool when hammering in smithy shop. It is made of
wrought iron. They are specified their weights. Main parts of the anvil are body, face,
tail, beak and cutting face. The punching hole is round and called as pritchet hole. This

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Workshop No. 7 Forging Workshop

hole is used for bending of small diameter rods and as a die for hot punching
operations. The square hole or hard die hole is used for holding square shanks of
various fittings.
c- Swage block: This is forging shop tool, used for many squaring bending, sizing and
forming operations. It is made of cast iron. It is a block having different type of
grooves on the face and channels on the four edges.
d- Hand hammers: Hammers are striking tools. They are specified by the weight and
shape. They are classified as Ball peen hammer, Cross peen hammer, straight peen
hammer, Sledge hammer etc. They are made of cast steel. The main parts of hammers
are peen, edge, cheeks and face.
e- Tongs: Tongs is a holding tool, which is used to hold the heated or cold work pieces
for striking. Tongs are classified as flat tongs, round or hollow tongs, ring tongs.
f- Chisels: Chisels are used for cutting metals.
g- Fullers: These tools are made of high carbon steel. They are used in pairs consisting
of a top and bottom fullers. Its working edges are normally rounded to make necks by
reducing the cross section of a job and also in drawing out.
h- Swages: Like fullers they are also made of carbon steel in two parts called the Top
and Bottom swages. Their working faces carry the circular grooves to suit the size of
work .They are used for increasing the length of a circular rod.
i- Flatters: They are made of high carbon steel and consist of a square body fitted with a
handle and a flat square bottom. They are used for levelling and finishing flat surfaces.
They are also known as flatters or smoothers.

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Workshop No. 7 Forging Workshop

Fig. 7.1Forging tools and equipment.

readings.

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Workshop No. 7 Forging Workshop

4. Laboratory Training

- Students should do an exercise for hand forging.

- Draw a schematic representation of the layout of the forging workshop.

5. Review Questions:
1. What is the main types of forging?
2. What are forging operations?
3. What are the main tools and equipments used in forging workshop?
4. Show with sketch the Hearth used in manual forging.
5. What is the function of: (tongs – anvil - Swage block).

6. Workshop Glossary

Anvil ‫سندان‬ Hammer ‫مطرقة‬

Bending ‫ثني‬ Hearth ‫موقد‬
Blower ‫منفاخ‬ Metal forming ‫تشكيل المعادن‬
Chisel ‫اجنة – ازميل‬ Presses ‫مكابس‬
Coke ‫فحم الكوك‬ Punching ‫تخريم‬
Die ‫ قالب‬- ‫اسطمبة‬ Welding ‫لحام‬
Drop forging ‫حدادة بالطرق المتساقط‬
Forging ‫حدادة‬

7. References
- Bruce J. Black, “Workshop Processes, Practices and Materials”, Third Edition,
Elsevier, 2004.
- Wikipedia

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