Agricultural engineering in development : intermediate blacksmithing : a training manual

70 Pages·1992·4.1 MB·English

by  Stokes, J. B

1SSM1010-1365
Agricultural engineering
AGRICULTURAL
SERVICES
in development BULLETIN
8/2
Intermediate blacksmithing:
atraining manual
BLACKSMITHSFIRE
metalin reducing part Fuelreserve
offiro
AshIx-d
Water-cooledblastpipe Clinker
(tuyere)
Food
and
Agriculture
Organization
of
the
United
Nations
FAO
Agricultural engineering
AGRICULTURAL
SERVICES
in development BULLETIN
88/2
Intermediateblacksmithing:
atrainingmanual
by
J.B.Stokes
Food
and
Agriculture
Organization
of
the
United
Nations
Rome.1992
Reprinted1999
Thedesignationsemployedandthepresentationofmaterialinthis
publicationdonotimplytheexpressionofanyopinionwhatsoeveron
thepartoftheFoodandAgncultureOrganizationoftheUnited
Nationsconcerningthelegalstatusofanycountry,territory,cityor
areaorofitsauthorities,orconcerningthedelimitationofitsfrontiers
orbound3n©s.
M-07
ISBN92-5-102739-0
Ailrightsreserved.Nopartofthispublicationmaybereproduced,storedina
retrievalsystem,ortransmittedinanyformorbyanymeans,electronic,
mechanical,photocopyingorotherwise,withoutthepriorpermissionofthe
caonpdyreixgthetntowonfetrh.eArpepplriocdautcitoinosnf,orsshouuclhdpebremaidssdiroens,sweidthtoatshteatDeimreecnttoro,ftIhnefoprumraptoisoen
Division,FoodandAgricultureOrganizationoftheUnitedNations,Vialedelle
TermediCaracalla,00100Rome,Italy.
©FAO1992
Preface
Aswiihthepreviousvolume,Basicblacksmithing,allpracticejobsdescribedhere
havebeenwell triedandtested.Again,thissecondvolumeis intendedtohelp
instructors whoare training blacksmiths forwork in rural areas in developing
countries.Thecontentsarenotintendedtobelessonplans,whichshouldbethe
responsibilityoftheinstructorsthemselves.Ihaveassumed,forthepurposesofthis
book, that the more modern welding processes(oxyacetylenc and arc)are not
available.IfthetechniquesinBasicblacksmithinghavebeenmastered,thework
explainedhereshouldnotpresentmajordifficulties.
AswithBasicblacksmithing,allsizesformaterialsareforguidanceonlyandwill
usuallydependuponthematerialsavailable.Toolsshouldalwaysbeofasizefound
mostusefultotheblacksmithandwillbeinfluencedbythekindofworkundertaken.
Goodhammers,effectivetongsandgoodsetsareessentialtoefficientwork.Theneed
for fullers, swages, set hammers and flatters will again depend upon thejobs
undertakenandthestandardoffinishrequired.
Blacksmithingshouldnotbeconsideredasanendinitselfbutratherasastarting-
pointfortherepairandmaintenanceofagriculturaltoolsandequipmentandpossibly
forsmall-scalemanufacturing.Wherepowersuppliesarcreliable,moremodern
techniquesshouldbeintroducedwhenpossible.Blacksmithingisatraditionaland
relativelylow-costmethodofdealingwiththeproblemsoffarmwork,particularlyin
areaswheremachineshopsarerare.
J.B.Stokes
This Ono
III
3WS9-WEH-8LW3
Contents
Preface Ui
PRACTICEJOBS
I FORGINGAWELDEDEYE-BOLT 2
2. ALTERNATIVEMETHODOFFORGINGANEYE-BOLT ±
3. BUTT-WELDUSINGACLEFTPREPARATION 6
4. RIGHT-ANGLEWELDEDJOINT.USINGACLEFTPREPARATION:
FORGINGARFNniMftnCKi 8
5. POCKETORCLEFTMETHODOFMAKINGAT-SHAPEDJOINT U
6. CORNERWELDINFLATMATERIALWITHDIAGONALSCARF 13
7. FORGINGAU-SHAPEDBOLTWITHSHARPINSIDECORNERS 16
8. FORGINGARFINFORCFDCORNFR 13
9. FORGINGBLACKSMITHS'TONGS 21
10. SHOULDERING-DOWNTOFORMTENONSANDROUND-SECTION
PEGSORRIVETENDS 30.
II THEPASIFSTWAYTOFOHGFHOTANDCO!DSFTS 34
12. FORGINGFULIFRSANDTOO!-HOLFSWAGESFROM
SCRAPMATERIALS 3J1
13. FORGINGTOPANDBOTTOMSWAGES 42
14. FORGINGSETHAMMERSANDSIDESETS 46
15. FORGINGAFLATTER 49
1fi. FORGINGASIMP!FRAII-PFFNHAMMFR 51
17. FORGINGANENGINEERSBALL-PEENHAMMER 54
18. SOMEAPPLICATIONSOFCASTIRONASAHARD-FACINGMATERIAL 57
GLOSSARY 52
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Practice jobs
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Intermediatehimksmithmx
1. Forging
a welded eye-bolt
FIGURE1
A
80 »
B *
C k *5)
FIGURE2 FIGURE3
FIGURE4 FIGURES
IntermediateMm-Lsmttlmx 3
Morataerpiiaelc.eM2i2l0dmstmeell.on1g2,masmdiensidrieadm.eter:ahandlength dcoioalmientgeradijsaciennctremaesteadlbwyitahbowuatte3ramnmd.upTsaekteunatinleatrh-e
weldingheatandforgeanabrupt,one-sidedpointonthe
Additionaltools.A14-mmdrift;holegauge: 12-mm endofthepiece.Inthesameheat,bendtheendaround
screwingdies. thedrift(Fig.3)togivetheshapeshowninFig. IB.
Takeafull-weldingheatandweld(Fig.4).making
METHOD useoftheroundededgeoftheanvil.Donotuseaswage
Eye-holts(Fig.1C)arerequiredlormanyapplications. forthisunlessithaswell-radiusededges.Trueupthe
Unweldedeyesaregoodenoughtorsomepurposes,but eyeoverthebeak(Fig.5).Ifasquareshankisrequired,
aweldedeyeisstronger.Examplesofusesinclude: merelyupsetalittlemoreandleaveasquaresection
spike-harrowspreaderbars,doorfixings,gatefixings, undertheeyeafterwelding. Eye-bolts withsucha
ox-cartsandploughs. squaresectionareusedinwoodtopreventtheirturning.
Markoffthemetal(Fig. IA).Takeanear-welding Itisimportanttotrueupwithaccuracytheendtobe
healbetweenthemarks,restrictthehealtothisareaby threaded.Useaholegaugetocheckthesize.
Copyrightedmaterial
4 IntermediateMaek\mtthinv
2. Alternative
method of forging an eye-bolt
Material. 140mmof12-mmdiameterbarandahand Calculation
lengthofthesamematerial. Insidediameterofring=30mm
Meandiameterofring=30±12mm=42mm
Additionaltools.A30-mmdiameterdrift. Metalrequired =42x3.14+metal
thicknessx2
METHOD 42x3.14+24
Thismethodisusefulformakingheaviereye-boltsand =131.88±24=155.88
similaritemswithlarge-diametereyes.Forpractice, =approximately156mm
again usea 12-mm diameterbar. but you may try
heaviersizesifyouwantto.Figure6illustratesthe Cutoffmetalrequired,heatandupsetbothends,bend
productionstepsbutleavesalldimensionsoptional. andadjust(Fig.7).Scarfinthemannerusedforachain
Assumeaneyewithaninternaldiameterof30mm. link,usingtheedgeoftheanvilorasmallfuller.Close
Calculatetheamountofmetalneededtoformtheeye upandfixthepositionofthescarfs(Fig.8).Takeafull-
andcutoffthatamount. weldingheatandweld(Figs9and10).leavingsurplus
FIGURE6
J
FIGURE7 FIGUREI
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htlcrmrjintchl,utumlhiin: 5
material slightly pointing outward from the eye threading.Useaholegaugetoensurethatthediameter
(Fig.10). isaccurate.Heattoadullredheatallover,cleanwitha
Theweldedjointisthenscarfedoveranedgeofthe wirebrushandallowtocoolintheair.
anviltogiveaV-shapedindentation(Fig.6B).The Takecaretoleavethejunctionoftheshankandthe
handlengthisthenupsetandscarfed(Figs6BandC). eyewell-radiused(Fig.6D).Donotuseaswageunless
Take a full-welding heat on both scarfs, position itiswell-radiusedtogivethecorrectsection.Theeye
(Fig.13)andweldwithlight,rapidhammerblows. mayberoundedupbyusinga30-mmdriftorgently
Reheatandmakefinaladjustmentstotheworkpiece. workingthepiecearoundthebeak.
Cuttheshanktolengthandchecktheenddiameterfor
IBUM9 FIGURE10