The attention of each is attracted by elegant twisted knots on the railing of iron stairs, as well as openwork metal fences. However, not everyone has the idea that such devices and items are made by cold forging.
If you wish, you can easily learn to embody such beauty in metal. To do this, it is enough to have specialized machines and have minimal skills in working with the material.
Features of cold forging
Mechanical bending of a metal rod with the help of specialized machines, as a result of which it is given a shape that was conceived in advance, is called cold forging. Such manipulations can be carried out on machines both manually using levers, and thanks to the functioning of electric motors. Among other things, with the help of cold forging pipes of small diameter can be bent, twisted fencing can be carried out, as well as residential buildings, gazebos, lanterns decorations, metal benches, grates, gates, as well as balconies, stairs and even furniture.
You can start your own production just by mastering the simple cold forging method. At the initial stage, you will need to purchase special equipment or make devices for cold forging with your own hands.
Equipment and tools
In order to make a forged product with your own hands, you need to have the following devices available:
- flashlight;
- twister;
- the globe;
- a snail;
- a wave;
- gnut.
Of all the devices listed above, the most important is the gnoot, since it is thanks to it that the shape of the metal is changed. Its main function is to bend the part at a certain angle. The cochlea is necessary for twisting the part in a spiral. The flashlight is used to bend parts, and the wave is designed to perform wave-like curved elements.
All the tools used for forging products are very easy to use and everyone can easily figure out their operation.
Advantages of Cold Forging Machines
In order for the metal to take the required shape under mechanical action, the cold forging method is used. Soft material is best suited for such purposes. The cold forging method is mainly preferred if you want to create a large number of identical elements.
Another indisputable advantage of this method of influencing the metal is that the creation process does not require the highest skill. If we compare cold forging with hot forging, then it differs in the following indisputable advantages:
- fast reproducibility;
- low cost;
- high manufacturing speed;
- coating strength;
- lack of heating elements.
Despite the fact that forged products made using cold forging have many advantages, they also have certain disadvantages. The main ones are the simplicity of forms and the need to use bulky and varied equipment.
Purpose and types of machines
The main purpose of any machine is to facilitate the manual labor of a person. In order to carry out forging in the cold type, various equipment can be used. In this case, the physical efforts of the master are significantly reduced, and the following actions are also performed:
- profile bending at the required angle;
- longitudinal twisting of workpieces;
- curls or spirals are made.
When using devices for cold forging, specific details are obtained that allow them to be built in a certain combination and create an artistic canvas. All machines designed for this metal processing method are divided into two categories: specialized and universal.
Can I make a machine with my own hands?
You can buy a cold forging tool only in a specialized store or make an order on the Internet. In this case, the entire acquisition process directly depends on the solvency of the buyer. If there is no free finance or there is no desire to spend quite a lot of money, then in this case you can easily make a machine with your own hands.
You can do without a machine, only in this case you will need to make every effort in order to achieve the desired result. There are two options for building a cold forging device:
As for the first, then in this case we are talking about a vice. The universal model is supplemented with certain elements (such as a basket or a lantern).
The device of machines
Without exception, all devices designed for cold forging have certain features and parameters. In order to start doing this not only exciting, but also profitable business, you need to have an idea of what each machine is used for. In the work of the master, the following types of devices are used:
- Bending machines. They are used to resize bends and waves. Bending on such a machine can be done with rods up to 16 millimeters in diameter.
- A twister is an aggregate equipped with a specialized template, directly to which the processed metal is pressed. At the same time, the pressure on it should be very large, since it is precisely on this that work efficiency directly depends.
- The base with spacers is designed to make patterns of absolutely any variation. Such mechanisms have a very simple design.
How to assemble a do-it-yourself machine?
Before assembling the device for cold forging with your own hands, you need to make sure that its base is strong enough. Only in this case the result will live up to expectations. As a support, channels or I-beams that are previously welded together can be used. It is also recommended that you attach paws from a similar profile to the support, and only after that you can begin to manufacture the remaining nodes.
Machine "Snail"
If there is a desire to make the machine yourself, then the "Snail" will be one of the most optimal designs. In order to do everything right, you first need to have an idea about the features of the machine. If the master understands the essence of the process, then in this case the design will not cause any difficulties. With the help of the drawing, do-it-yourself cold forging appliances are made relatively easily. The most important thing is to follow all the recommendations and carefully carry out all the steps.
First of all, you need to take care of the presence of a solid frame. It is not recommended to make it from wooden bars, since it will not be able to withstand prolonged loads. The most optimal option is the use of a thick-walled pipe, metal corners or channels.
From a metal plate, two worktops must be cut in the shape of a circle. It is this element of the device for cold forging of metal that will take on the bulk of the load, so you can never save on its quality.
It is also worth taking care of the availability of other necessary parts, which include a lever and a shaft. You can make a shaft for a homemade device for cold forging from a thick-walled pipe of the required diameter. A lever is attached directly to it with the help of a ring, which rotates around it. Additionally, a roller for bending the rods is required on the lever.
As soon as all the necessary elements are ready, you can proceed directly to the assembly of the machine. All actions are performed in the following sequence:
- First, the frame is installed in such a way as to ensure unhindered access from all sides;
- then the legs of the machine are concreted or fixed;
- then the main countertop is welded to the frame;
- the main shaft is installed and the countertop is welded;
- the element is strengthened with special triangles and a rotating lever is put on it.
- after that, the upper countertop is installed and welded to the main shaft;
- assembly is completed by mounting snail segments on the countertop.
As soon as the assembly of the DIY cold forging tool is completely completed, a trial bending is carried out. This operation is mandatory.
Torsion bar machine
For uniaxial longitudinal twisting, a torsion-type cold forging tool can be made. For the foundation in this case, it is necessary to prepare a tee or channel.
After that, an iron strip should be attached to it by welding, on which a vice for clamping will be directly installed. They are securely fastened with four bolts. The next step is to weld corrugated plates onto a vice and install guide rollers. A clamping unit is attached to the latter, which ensures the mobility of the workpiece.
Next, a special handle is made, which serves to rotate the movable part of the clamp. After the completion of all work and the complete assembly of the machine, it must be checked for strength and performance. Only then is it finally fixed to the support frame.
Machine “Gnutik”
In order for each product to be manufactured with high quality, machines and devices for cold forging in the workshop must be of various types. To form an angle, a “Gnutik” is needed. It is assembled from a special steel plate on which a lever and two support shafts are fixed. Making such a device for cold forging of metal with your own hands is quite simple.
If it was decided to engage in the formation of products, then you should definitely take care of the presence of a machine called “Gnutik”. Making it is quite simple. It is sufficient to clearly follow the drawing of the cold forging tool. It is also important to use tool steel.
Machine "Wave"
According to the photo, the “Volna” cold forging tool consists of a pair of steel disks mounted on a worktop with an axis of rotation.
It is controlled by the method of changing the distance between the disks. In the process of processing the bar, a pattern is formed, then it is removed and the process is carried out on the other hand.
Press machine
To form the tips of the rods, you must have a press. To make such a device for cold forging of metal with your own hands, you need to order gears, shafts, rolls and bearing bushings. All of these items are purchased at the store.
The unit functions as a result of rotation of the rod with the loads and retraction back to the stop of the screw striker.
Manufacturing nuances
Despite the fact that many machines designed for cold forging are relatively simple to construct, it is recommended that you familiarize yourself with the information and all the nuances of manufacturing before creating them. This must be done so that during the assembly process there are no unforeseen circumstances that could adversely affect the quality of the product.
Before proceeding directly to the design of the cold forging machine, it is necessary to draw up a drawing in which all the features of the future fixture will be identified in great detail. After the scheme is ready, you need to purchase and prepare all the necessary details. Only then can you start assembling.
Before manufacturing the machine, you need to prepare a bed so that all the parts for the construction are located at hand. All parameters must be accurately calculated so that the devices do not interfere with each other. For the manufacture of the bed, experts recommend using only durable material.
Features of joining and painting parts
Once the manufacture of cold forging accessories is completed, you can proceed directly to the implementation of artistic elements.
After the manufacture of parts, they should be interconnected. There are several ways to do this. Often the elements are connected by welding. After fixing and cooling, the resulting scale is grinded.
A much more beautiful method of connection is the use of clamps, which are stamped strips of metal. As soon as all the elements are fixed among themselves, they are painted. For this, blacksmith enamels or acrylic-based metal paints are used.
Powder formulations may also be used, but the technology will be relatively expensive. Before applying the enamel to the surface, the latter must be carefully prepared. Do not apply to rust and dirt. The surface must be degreased and free from corrosion. Only in this case, the enamel will last as long as possible on a homemade tool and protect it from moisture.
To summarize
Before you begin to create metal artwork, you need to take care of the availability of all the tools and appliances for cold forging. All work must be done carefully and carefully. Only in this case can an ideal result be achieved.
In most cases, making machines for cold forging is much more profitable with your own hands. These devices play an important role and are necessary for the production of quality products. This is due to the fact that far from every element it is possible to process using hand tools, and the cost of most machines is quite high, even when it comes to the most elementary units.
Many craftsmen prefer to make machines on their own, which help to make rather original products. In this case, it increasingly depends on the experience of the master and his desire. If a decision is made to construct a machine with one's own hands, it is important to perform all actions in a certain sequence, then the result will exceed all expectations.