You will notice that many of them have the standard anvil shape, while others are simple sheets of iron. Here's a good reminder of what the most important features of anvils are:
- They must be stronger than the metal they are working with
- They have enough mass to distribute the applied force evenly across them
- The anvil's workspace is at least wide enough to accommodate the portion of metal you are working with
Moroccan anvil
This blacksmith shows the kind of DIY ingenuity we prefer. He appears to have removed the base of the anvil, presumably for safer use. You will notice that his shoulder is still slightly curved while the hammer is in contact with the surface of the anvil. Over time this keeps him from putting unnecessary strain on his shoulder
Basic methods of forging metal
Hot forging
As already mentioned, hot forging is possible if the metal is heated to temperatures where it changes its strength characteristics and becomes plastic, which makes it possible to process it relatively easily using impact tools and other devices.
The hot processing method involves the use of special metal processing technologies, which make it possible to make the finished products more diverse. But besides the advantages, there are also some disadvantages of the method. These include the fact that heating the metal requires the presence of a forge or muffle furnace. Let us note that such equipment, in addition to its price, will be expensive in the future when used, since you will need to pay for its maintenance and fuel.
Also, using an open source of fire is far from a safe activity and requires craftsmen to adhere to increased safety measures. In addition, hot forging requires that the craftsman have certain knowledge and skills to understand the temperature parameters of different types of metal.
Hand forged
Hand forging of metal must be done in special workshops that are equipped with everything necessary.
The list of equipment includes the following equipment:
- Air exhaust system.
- Muffle furnace or forge.
Cold forging
Most cold forging work is performed on equipment designed according to special drawings. You can list a specific list of equipment that should be used in cold metal processing. Typically, such equipment can show its effectiveness when performing a large volume of work for the architectural design of structures and buildings.
Among the equipment that is used to produce products using the cold forging method, we name the following:
- Torsion bar, with it you can twist the rod around its own axis.
- Wave, wavy parts are made on it.
There are only a dozen units in the equipment park for cold forging. Some of them can work from the operator's muscular system, while others work from the drive. Some craftsmen make similar equipment themselves, and also create modifications.
Myanmar anvils
Another example of an anvil in the form of a steel pillar, but this time it is supported by wooden supports around its base. A steel cylinder, hand-made wooden supports and a hole in the plywood base - all this you can easily install at home
DIY mechanical hammer
You can make a homemade hammer for forging in several stages:
- Preparing the foundation for installation.
- Creating a machine frame.
- Assembly of the mechanism.
- Installation of the device.
But before you begin manufacturing the entire structure, you need to decide on the dimensions of such equipment, which will subsequently determine its weight and capabilities. Examples of devices are shown in the diagram.
The easiest way to make a forging mechanical hammer, shown in option “A” with a horizontal arrangement, it will be more stable.
Foundation
Having made a drawing of the future device, they begin to prepare the foundation. It is needed for normal operation to prevent the hammer from tipping over and dampening the impact force.
A hole of the required size is dug at the installation site. Sand and crushed stone are poured into the bottom, watered and compacted. A reinforcing frame made of 12-14 mm reinforcement is mounted on top, always with bandaging in increments of 250-300 mm.
Concrete is prepared in a ratio of 1:2:3 (cement grade M400, crushed stone fraction 10-20, and sand).
Filling should be done at a time, constantly trying to compact the mass to avoid voids inside.
Upon completion, anchor bolts can be installed in the uncured concrete, onto which the installation will then be additionally attached.
Frame
The frame material is selected depending on the installation parameters and dimensions of the parts being processed. Either a profile pipe or a channel will do. You can also use other convenient rolled metal.
The frame is assembled by welding. Additional spacers and cross beams must be installed.
Mechanism
The main working part - the lever with the striker and counterweight - can be monolithic or prefabricated. The metal must be solid (not a pipe), otherwise the rod will gradually deform under the weight. Such a lever can be “collected” from strips by welding them together.
The firing pin must be made of tool grade steel and, preferably, hardened for greater strength. It needs to be welded to the lever.
Any heavy metal or other material will be suitable for a counterweight.
It is also better to make the shaft on which the hammer will rotate from a solid piece of steel. The lever itself with the hammer is fixed on the axis using transverse pins. The shaft in the frame must rotate freely, so it is best to equip the ends with appropriate bearings.
The drive pedal and transmission can be welded from a regular profile pipe to the required size. Moreover, the control lever itself must move freely. Bearings or simply pieces of pipe into which the shaft with the pedal are mounted are also suitable for this.
Hammer assembly steps
Initially, you need to assemble and install the frame of the device on the foundation. The lower slide is mounted on anchor bolts with nuts. The remaining guides and jumpers are welded to them.
A shaft is inserted into the racks, onto which a lever with a hammer is fixed.
The assembly of the drive with a pedal or lever is also carried out.
The anvil itself can be made from a piece of rail, I-beam or channel. However, it is desirable that the front part be hardened.
After final assembly and testing, the structure must be painted.
What can you add to this material from your personal experience in making such devices for forging metal? What designs have you used? Share your ideas in the block for this article.
Indian anvil
To complete our tour of the world of anvils, take a look at a photograph of an Indian blacksmith transforming a pistol barrel into a plowshare. His anvil is on the ground just behind his campfire. He forges steel while squatting.
Thanks for exploring some examples of anvils around the world. If you have any photos that you would be happy to share from your travels, post them in the comments
Author - Terran
Horns
A blacksmith’s “work table,” depending on the type, may have one or two horns; their number determines the shape of the product. If only one is present, it has a cone-shaped, rounded configuration. In the case of two horns, one is rounded, and the second may have a pyramidal shape (more often called the tail).
The purpose of such an element is to perform the function of a mandrel on which bending of strips or rods is performed, as well as rolling or welding. If there is a second pyramidal one, then bending and straightening of blanks is carried out on it, or products of other complex shapes are forged.
Some types of anvils between the face and the horn have an unhardened part of the platform; metal is cut on it with chisels.
There is often a round hole near the horn and a square hole in the tail. A circle-shaped section (15-25 millimeters in diameter) is used for stitching workpieces (instead of drilling), a square section is a kind of installation point for additional devices (lowers). There may also be two round holes with different diameters (depending on the type of product).
Features of the use of hammers of other types
A pneumatic hammer installed in a single unit is usually equipped with an individual compressor unit. This type of pneumatic hammer does not have a high mass of falling parts, and therefore can be used for forging small products. A pneumatic hammer usually has a C-shaped frame, which is fastened with side posts for rigidity. The stamping area of the pneumatic hammer is thus open on three sides, which facilitates its maintenance.
The hydraulic hammer has limited use. Hydraulic forging units are often used in hot sheet stamping, when processing titanium alloys that have low plasticity in the cold state. The speed of the die in hydraulic hammers is lower, which is explained by differences in the density of oil/water compared to air/steam. The hydraulic actuator requires increased requirements for sealing seals; otherwise, its design is not fundamentally different from other schemes of the considered installations.
Mechanical drives of impact forging machines - with a belt, board, or spring-spring - are now rare, since in this case additional energy cannot be supplied to the deformation zone. Their design is quite simple, but the efficiency is low.
