Admiring the beauty of an openwork metal fence or admiring the incredible twisted pattern on the railing iron stairs, few people think that they are made using the method cold forging. You can learn to embody beauty in metal without special effort. To do this, it is enough to have minimal skills in working with metal and have special machines for cold forging.
What is cold forging? What machines are needed for it? What can be made on these machines? You will find answers to these questions in our article.
It would be more correct to call cold forging - mechanical bending of a metal rod on specialized machines to give it the shape intended by the manufacturer. Bending rods in the machine can be done either manually using levers or using electric motors. In addition to the metal rod, the cold forging method can be used to bend pipes without large diameter, narrow iron strips and fittings. Using the cold forging method the following are produced:
- Twisted fences.
- Decorations for residential buildings.
- Patterned gate.
- Railings for balconies and stairs.
- Metal garden benches.
- Decorations for gazebos and lanterns.
- A large number of grating options.
Elements made by cold forging Having mastered the cold forging method, you can easily start your own business producing metal products. At the same time, you will only need initial financial investments for the purchase of machines, and if you make the machines yourself, you can get by with minimal costs.
Below we provide you with instructions for self-assembly machines for cold forging.
Machine "snail"
Making a snail machine is one example of independent design, and it makes no sense to give advice with an exact indication of the dimensions of all parts. You need to be guided by your idea of the operation of the machine, how and what will bend, how many turns of the spiral will be enough for quality work, what size will the lever with the tabletop be? If you understand the essence of the machine manufacturing process, then the assembly itself will not cause any particular difficulties.
Machine “snail” Manufacturing of main machine components
Frame.
The process of bending an iron rod exposes the machine to heavy loads, so when making the frame for the “snail”, only metal corner, channel or thick-walled pipe. Don't make a frame out of wooden beams, such a table cannot withstand prolonged loads and collapses.
Tabletop.
The tabletop for the “snail” is made from metal plate cut in the shape of a circle, at least 4mm thick. From the same slab, a second tabletop is cut out, repeating the shape of the first. The snail segments will be placed on the second tabletop and the products will be bent. During the cold forging process, the tabletop takes on the bulk of the load, so there is no need to save money and make it from more thin sheet gland.
Main shaft and lever.
The main shaft is placed centrally between the tabletops and is attached to the base using four right triangles. The shaft can be made from a thick-walled pipe required diameter.
The lever is attached to the shaft using a ring and rotates around it; in addition, a roller is installed on the lever for bending the rods on the upper tabletop.
Machine diagram Marking and installation of attachments
Depending on whether you want to produce only the same type of samples or you need more artistic products, there are three options for the snail device.
Option #1.
This is the simplest of three options, its essence is that the outline of a spiral is drawn on the tabletop.
Drawing of the snail segments At its core, this is a drawing of future products that you will produce on the machine. After applying the diagram, it is enough to cut out thick strips of iron different widths, several segments repeating the line of the drawing and weld them according to the markings to the tabletop. With such a static “snail” you can make simple bends.
Option #2.
The second option is the most popular among homemade machines; it involves making a collapsible snail from removable parts. Holes are drilled along the contours of the markings into which threads are cut. Next, templates for the stop segments are made from cardboard or plywood and metal overlays are made from them. Finally, holes are drilled in the pads, which should coincide with the mounting sockets on the tabletop. To secure the segments, bolts are mainly used, but you can also make cylindrical stops. This design“snail” will allow the production of spiral-shaped blanks with different radii on one machine.
“Snail” made of metal strips Option #3.
In the third option, instead of collapsible stop segments, several removable modules with different options snails that change as needed. The module is made of a piece of iron onto which segments repeating parts of the spiral are welded.
Snail modules Machine assembly.
- Install the frame in a place where you will have easy access to the machine from all sides.
- Concrete the legs of the frame in the floor or secure the frame in another accessible way.
- Weld the main table top to the frame.
- Install the main shaft by welding it to the tabletop and strengthening it with triangles.
- Place the rotating lever onto the shaft.
- Install the top tabletop by welding it to the main shaft.
- Place the snail segments on the tabletop.
After assembly, test bend the rod.
To learn more about assembling a snail cold forging machine, watch the video:
Torsion bar machine
This machine is designed for uniaxial longitudinal twisting of a workpiece from a transverse or square shape.
Torsion bar machine A channel or I-beam is used for the base of the torsion bar machine. A thick iron strip is attached to it by welding, onto which a vice is installed to clamp the stationary part of the rod. The vice is secured with four bolts with a diameter of M16 or more. To increase the clamping strength of the bar, corrugated sheet steel plates are welded onto the vice. On the opposite side of the base, guide rollers are installed, to which a clamping unit for the movable part of the workpiece is attached. It is made of a steel bushing, in which it is necessary to provide holes for clamping bolts located at an angle of 120 degrees. The bolts must have a flat end and be made of high quality steel. Both clamping devices must be positioned coaxially; to do this, they must be checked using a level, a plumber's square and a caliper.
Types of machines Next, you need to make a handle for turning the moving part of the clamp. Its lever should hit as long as possible to reduce the applied force. It is better to make the handle itself with a rubber bushing to prevent the hand from slipping during operation.
After complete assembly The machine is checked for the reliability of the moving elements and the accuracy of the deformation of the rod. After checking, the machine is attached to support frame.
Simple model torsion bar machine How to make a torsion bar machine with your own hands, watch the video:
Machine "gnitik"
To qualitatively form a corner in a product produced by cold forging, you will need a machine called a “bend”. It consists of a steel plate with a movable stop on which there are two support shafts and a lever.
Machine “gnutik” The workpiece is placed between the wedge and the support shafts. After this, with the help of a lever, the wedge is shifted towards the shafts, which leads to bending of the workpiece.
Computer model machine Making such a machine is quite simple, the main thing is to follow the given drawing and use tool steel, since during operation a large load is placed on part of the device.
You can also watch how to make a “gnitik” machine in the video:
Wave machine
It would be more correct to call this machine a controlled wave. The equipment of the machine consists of a pair of steel disks with a diameter of 140 mm, which are bolted to the worktop. The axis of rotation of the universal wrench is fixed to the drive disk.
Machine “wave” Wave control occurs as a result of changing the distance between the disks. When the bar is rolled around the drive disk with a knob, a pattern is formed, after which the bar is removed from the conductor and a pattern is formed on the other side.
You can watch the machine in action in the video:
Press machine
A press is needed to form the ends of the rods. This machine works on the principle of a flywheel; first, by rotating the bar with weights, the screw striker is pulled back until it stops. After this, a replacement stamp is inserted into the slot and the workpiece is placed. Next, quickly unwind the barbell in reverse side and leave it to rotate freely. Finally, the striker hits the stamp shank strongly, due to this, a force sufficient for stamping is developed.
Rolling press As for the manual rolling mill, you can make it yourself, but you still have to order special steel rolls, bearing bushings and shafts, and buy gears in the store. Only tips can be produced on such a machine “ goose foot" and "leaf".
Connecting and painting parts
Elements produced by cold forging are connected in two ways:
- Welding - the parts are welded to each other, and the scale is ground off with a grinder or other grinding machine.
- Clamps - this type of connection looks much more beautiful. For clamps, stamped strips of metal with a thickness of 1.5 mm or more are used.
Painting finished products produced with blacksmith enamels or paints for metal on acrylic base.
Connecting parts using welding Products produced by cold forging
We invite you to familiarize yourself with the options for products that you can make using the cold forging method:
- The fence element is completely made using the cold forging method. Clamps are used to connect the parts. The following machines were used for manufacturing: “snail”, torsion bar, “bend” and “flashlight”.
- Soda bench - made by cold forging and covered with wood. Welding and clamps are used to connect the elements. In production, machines were used - “snail”, torsion bar, press.
- Balcony railings - production method - cold forging. The railing elements are connected using welding and clamps. The machines used in production are “wave”, “snail”, press.
- Stair railings - produced using the cold method artistic forging. The parts are connected by welding. The machines used in production are torsion bar, flashlight, and snail.
- Visor - the frame of the visor is made using cold forging. The parts are connected by welding. In the manufacturing process, machines were used - “snail”, “wave”, press.
- The grill is a simple design made using the cold forging method. Clamps and welding are used to connect the parts. The barbecue elements were produced on machines - torsion bar, "snail".
- Double bed - cold forging method is used for the backrests. Connections are made by welding and clamps. In the manufacturing process, machines were used - “snail”, “wave” and press.
As can be seen from all of the above, the cold forging method does not require large financial costs and is quite easy to learn, so if you decide to start learning blacksmithing with this method, then you did the right thing.
Anvils, furnaces, powerful blacksmiths in leather aprons - this is all about hot forging and classical blacksmithing. There are professionals, expensive equipment, separate premises - it’s not a cheap job. We are talking about a completely different process - cold forging.
If you look at it, this technology is not forging. It would be more correct to call it bending metal rods; sometimes it is called “flexible”. But, since the term “artistic cold forging” has already been established among numerous ranks of metal craftsmen, we will use generally accepted terms.
All artistic forging consists of continuous bends, waves, curls - all of them different sizes, in various combinations. You cannot bend metal with your hands, even if it is the softest. Therefore, the only main method of cold forging is metal processing by machine. For each metal element there is a tool.
Examples of artistic forging.
The first thing you need to do is get them, but first understand the types of cold forging machines. The complexity of such equipment is low, and so is its cost.
If you are going to do blacksmithing for yourself, a few hand-cranked tools will be enough for you. The pace of work on manual equipment is slow, but the costs of production and use are much lower. Electric drives will only be needed in cases of commercial forging to order, then the game will cost the candle.
Special ones are whole bouquet options, they come with manual control or with electric motors, homemade or purchased. To embody all conceivable and inconceivable artistic ideas in metal, 5–7 types will be enough. At least half of them can be made yourself.
The main thing is to remember that cold forging of metal is possible for anyone who has the desire and perseverance. Before deciding to start cold forging work, you need to understand some of the nuances of this technology and the types of special equipment.
Classification of machines
Types of machines for cold forging.
Cold forging machines are divided into four main types:
- twist the spirals with flat surface and narrow cores, these machines are most often used for manual cold forging.
- Torsion types of devices designed for the production of twisted volumetric spirals.
- Bending types– for spirals with wide cores.
- Inertia-stamping– for decorative clamps and processing the ends of all elements.
Before detailed description For each type, we’ll go through cold forging technologies, there are only three of them:
- Hood: This is the rolling and elongation of a metal blank, the process is similar to rolling out dough with a rolling pin. In forging, pressing rollers work in this way. Using this technology, paws, clamps, and peaks are prepared.
- Torsion: twisting the part along the axis, see below for a detailed description.
- bending: bending metal according to patterns in different directions.
Twisters or snails?
Description of forging machines.
Both of them are one and the same. The most popular cold forging machine among the general forging community. Indeed: at first glance, the machine seems too primitive.
But in it simplicity is combined in half with genius:
- it’s easy to make it yourself;
- it's cheap;
- it is extremely easy to use;
- with its help you can make entire arrays of beautiful metal lace.
According to the principle of operation, twisters are a type of bending machines, see below about them, with some improvements, beginners can easily work on them. In a word, a snail or twister is an amazing machine in terms of all possible criteria: ease of manufacture, wide artistic possibilities, low cost and ease of use; there are simply no others like it.
Twisters are found in two engineering versions:
This snail has weaknesses, what would we do without it. It's all about the folding share: both the correct material from which it needs to be made and the complexity of making the joints of the share links are important. These joints must be extremely precise - they are the ones that create the shape of the curl. The design and material of the joints must take into account multiple repetitions of turns with severe workloads. Second and last weakness – eccentric clamp details.
Taking into account the frequency of use of the snail and its weaknesses The smartest thing to do would be to buy it rather than make it yourself. If we are talking about a debut in cold forging, and the choice of machine is made for an absolute beginner, then the most the best option there will be a second engineering version of the snail.
- Champion in popularity and positive aspects of work! Lever volute with a fixed template and a deflection roller. At its core, it is a pipe bender. It should be immediately noted that this option is inferior in labor productivity to a twister with a collar and a plowshare. Secondly, no tabletop is suitable for it; here you will need a real steel frame with fastenings on the supporting surface. You can’t install a bed at home: you can only work on a lever volute in a workshop.
Machine for giving a relief surface.
Another feature of the lever volute is the slow pace of work. You can curl 3 – 4 curls, a little less than with a collar snail. However, the advantages of the lever snail outweigh all its disadvantages:
- All elements of the machine can be made of ordinary steel.
- Instead of a pressure roller, which is not made of ordinary steel, you can use a bearing.
- The material of the bed and other parts allows you to count on long-term use of the machine.
- Greater variety of curls - you can change their shapes with bends in both directions (in the first version of the snail this is impossible).
- It is more convenient to work with the ends of parts that can be fastened.
On a lever twister you can work with strips of metal laid flat. This is considered a great advantage of the machine, since it is impossible to work on other devices with flat strips.
In this championship subsection, you can make a small championship summary in the form of advice for beginners: in the opening artistic works For cold forging, it is better to start with a lever twister - a snail with a fixed template and a deflection roller.
Torsion bars from the word torso , torsion bar machines
Curl technology.
Twisting along the torso, and that says a lot. The torsion bar machine for cold forging is designed for helical longitudinal twisting of rods. If you figure it out, you can twist them without a machine: just hold one end in a vice, place a block of wood under the other end, and twist the rod in the guide pipe. Everything is simple, but today we are talking about artistic forging, so the quality of twisting, taking into account the smallest nuances, is the number one requirement. Therefore, it is better to twist the rods, either along or across, using machines.
Unlike twisters, torsion bar equipment can be made independently; the vast majority of torsion bars among people are homemade. These machines also require a strong frame with equally strong fastenings on the supporting surface. The rods in the correct torsion bars are held in square-section chucks, which are secured with clamps.
Everything would be elementary if among the cold forging masters artistic figures such as a basket, a lantern or a cone were not considered especially chic - figured thickenings made of several twisted rods. All of them are called mysteriously - filaments. To make them, you need to insert a bunch of smaller rods into the torsion bar, most often 4 - 5 pieces.
You will have to tinker with cones and lanterns - branches made of twigs need to be spread in width manually, which is very difficult and requires decent skill. For high-quality filaments, the pride of blacksmiths, special headstocks with screw-fed spindles are attached to torsion bars. Troublesome elements, but for the embodiment of artistic ideas and aesthetics of metals - nowhere without filaments.
Bending dies.
Attention! Torsion bars are the only cold forging equipment that electric drive justified and appropriate for any amount of work. This is indeed true, it is painfully tedious and tedious work with a manual spindle drive. But it is not main reason. Manually It is impossible to achieve uniform twisting; this requires very uniform rotation.
Inertial stamping machines
This type of equipment resembles presses or pressing rollers, which are sometimes neglected by young craftsmen. But in vain: without shaped clamps for connecting parts and decorated rod tips, the work will never have an aesthetic appearance. These presses work like a flywheel in which the firing pin hits the die area. Decorative parts are small, the accuracy of their manufacture must be very high, so you don’t even need to try to make this type of machine with your own hands.
Everything would be fine, but inertial stamping presses are an expensive pleasure. But here you can find a solution, let's call it an “integrated forging solution.” Various kinds The tips are very easy to make using hot forging. You don't have to be an experienced craftsman to do this. Either go to a hot forging workshop or start an elegant forge yourself - you can easily and inexpensively make it from scrap materials. For such small work, you don’t need your own separate forge; there’s nothing to do - just heat up the metal.
Bends or bends
In practice, they are more often called “bends”. But among forging masters, the gnutik is the most popular cold forging machine, which makes metal waves and zigzags. This equipment is desktop and quite simple in design. But it’s better to buy it than to make it yourself. The fact is that this type of forging requires very high precision in processing parts. A bend for cold forging is quite inexpensive, especially for pipes smaller than 12 - 16 mm.
Another thing is bending, which is much simpler than bending: it is bending a rod at the desired angle. Folds are made using templates. First, a drawing for the template is drawn, then a curl is welded onto the steel plate. Forging involves pulling the product through all the curves of the curl.
It is still possible to make manual cold forging machines with your own hands. The only part of such a machine that you will need to buy is the rollers. They need to be made only from special steel: either tool steel or chromium-nickel steel. The cold forging equipment itself can be made of brackets and arcs with stops that will define the contour of the wave. The waves can then be as varied as required.
DIY machine
Machine for bending rods.
A homemade tool for cold forging is a very real thing, but its production will take a lot of time and effort. Therefore, the decision must be balanced, and the preparation, including drawings, must be serious and complete. The most suitable place can become a garage shed, or a utility block. The design of the machine depends on only one factor: what are you going to do, what products to produce?
We must not forget that many forging elements can be performed without special devices. For example, using a regular pipe bender, which is quite suitable as a version of a simplified machine for cold forging - you can do a lot with it.
You also need to understand that a universal machine for cold forging that would make at least three various element, does not exist in nature. Most often, they make a snail with their own hands: it is popular, allows you to make a wide variety of curls and, in the end, is easy to make. The second most frequently used tool at home is a homemade bending machine.
It is also simple and inexpensive to implement. When you search for “how to make cold forging machines,” you will receive a huge number of links to videos with tips from “experienced people.” Most of them are to the point and from the heart, they will greatly help in making final decisions.
Connecting parts and painting
Now all the curls need to be collected into a single canvas. The work is not easy, but very rewarding: it is at this stage that the main artistic idea begins to be realized. Meanwhile, at this stage you can easily ruin everything. This is easy to do: start connecting the parts by welding, and then use a grinder to clean them.
But we have already talked about the professional ambition of cold forging masters, which can only be welcomed. Special U-shaped clamps, which are stamped on inertial machines, will look much more impressive. Don’t be lazy, but work well with the clamps - this is the key to successfully completing the forging of the product.
Torsion of metal on a machine.
Now about painting. Thank God, now there is something to paint: thanks to modern construction technologies, there are a huge number of paints on sale for every taste, budget and, most importantly, purpose. There are countless paints for metals. Most often, special acrylic paints for metal or forge enamels.
Very often, for completely unknown reasons, blacksmiths prefer finishing coat paint with pigment from a forge patina - “antique”, while showing an amazing unanimity in tastes. If you are a forging customer, then you need to stop the craftsman in time to offer him your own version of the color and texture of the coating. But seriously, who said that forging should be dark and antique? And the white one? Colored? This is where there is vast space for the most daring artistic solutions.
Summary like clockwork
Types of stamps and ready-made curls.
A good story is always easy to finish - the conclusions fall on their own, within the framework of logic and priorities.
In our review of cold forging technology, the harmonious conclusions are clear:
- Cold forging is a wonderful technology that allows you to combine what is impossible to combine in other processes:
- practical benefits on the farm;
- the possibility of artistic creativity;
- invention and application of own engineering discoveries;
- simplicity and reality of implementation for beginners;
- increasing self-esteem as a craftsman and as a resident of a house with elements of artistic forging.
- You can make devices for cold forging yourself and with high quality, it is better to start with snail and bending machines.
- It is more expedient to make manual equipment with a manual drive. Electric option use - too resourceful. The only type of machine that is best made with an electric drive is a torsion bar one. The quality of twisting the rods will be much higher in this case.
- In the manufacture of forged products using the cold method, “help” from hot forging will not hurt. Machine for tips and other small decorative elements It’s impossible to do it yourself, and buying it costs a lot of money. Our advice is to make decorative details using hot forging. A small and neat forge in the household will not hurt. And it will contribute to professional growth: start with cold forging, come to real blacksmithing...
- You shouldn’t get stuck in the stereotypical “antique” painting of forged items. Modern colors and widespread eclecticism in design make possible the most unexpected color and texture solutions in metal work.
This type of working with metals is more popular among “home” craftsmen, if only because it does not involve heat treatment and, therefore, the installation of a forge. And this matter is both more complex and troublesome. And the technology for manufacturing various patterned parts is much simpler, since there is no such thing as “overheated” or “underheated” material.
In principle, cold forging can be done using hand tools- Special equipment is not always necessary. All you need is an anvil and a hammer. This way you can work with almost any workpiece - sheet iron, metal strip, rod or pipe. It all depends on the complexity of the part and the skills of the craftsman. By the way, as an option - a regular one, which can do a lot of things.
But in most cases, especially for passionate people, or if the business is on stream, it is advisable to use a cold forging machine, even a home-made one, since not every sample can be processed with a hand tool. And the range of possibilities is expanding significantly. There are many corresponding devices on sale, but their prices are steep.
For example, the cost of the cheapest universal block(forging and bending) is approximately 120,000 rubles. And this does not take into account accessories, which, depending on the configuration, will cost another 7 - 10 thousand. the simplest machine for the “snail” you can’t find it for less than 65,000.
You can assemble simple mechanisms on your own, which, nevertheless, allow you to obtain the most intricate patterns. It's all about the skills of the person who will work. Let's consider one of the models, without indicating the material used, dimensions and other subtleties. The main thing is to understand the principle of the device, and everything else House master will select it himself. Moreover, a person who has no inclination to engage in such “construction” will not be interested in this.
Machine "snail"
With its help you can make rings, spirals, “waves” and various “curls”. The machine manufacturing process includes several stages.
Sample
To obtain greater marking accuracy, it is advisable to use graph paper. A spiral is drawn on it, with a gradual increase in the radius of the turns. The condition is that the distance between them (step) must be the same. But this is if symmetry of the pattern is required (although each person has his own concept of the “artistic value” of the work). The same applies to the number of turns (as a rule, there are no more than 4).
You need to consider what workpieces you will have to work with. The “step” should be slightly larger than the diameter of the rod (strip iron), otherwise pull it out finished part It’s unlikely to come out of the machine without damaging the “mold” after the operation is completed.
Working surface
A piece of sheet iron is used. Its sufficient thickness is 4 mm. Linear dimensions are determined based on the expected dimensions of the parts being manufactured.
"Form"
For it, you can take, for example, strip metal 3 mm thick. This will allow you to work with it using hand tools. It bends into a spiral according to the markings of the template. This is easy to do using a pair of pliers.
Additional items
To ensure the working process, you will need to fix one end of the workpiece. Therefore, you will need a piece of rod (equal to the width of the strip). In addition, the working platform will need to be secured to something (for example, a workbench). As such a stand, you can prepare a 10-centimeter piece of pipe (thick-walled, of course). Although there are many options here, since a structure installed in this way can interfere with other types of work.
For example, provide for securing the entire assembly in a “powerful” vice. Therefore, instead of a pipe, you can take a hexagon (large diameter nut or something similar). The main thing is the reliability of the fixation, given that during cold forging you will have to make significant efforts.
Machine assembly
There are also many options here. It can be made either “monolithic” or disassembled into its component parts. In the first case, the “snail” (or its individual parts) from the strip is simply welded to the site. For example, in this situation:
You can “weld” pieces of the rod along the entire length (1 cm each) at intervals of 4–5 cm, and drill mounting holes for them in the working area.
The main thing is not to forget about securely securing the end of the bent part.
We considered only one of the simplest options. To have a more complete understanding of all the possibilities of devices for making “snails” and so on similar products, it is advisable to become familiar with the relevant industrial equipment. How to do it required device A savvy person will always figure it out on his own, using available material. An interesting option is shown in the video:
In practice, you often have to bend workpieces into a “snake”, but doing this by hand is quite difficult. Such machines are called “torsion bar”. In addition to the fact that considerable effort will be required, it is necessary to maintain uniform rotation. This means that such devices for cold forging will have to be equipped with an electric drive. You can see the complete list of equipment for cold forging.
When a person learned to work with metal, he radically improved his standard of living and changed it thoroughly. This was felt not only during the war, but also in everyday peaceful life. She became much more comfortable and beautiful. Through cold forging, craftsmen make amazing things from metal.
Which, in principle, is very simple. It is enough to have the desire, experience and special equipment.
Cold forging products
Essentially, this is bending and twisting metal products without heating them in forge furnace. For this purpose, various machines are used, differing in size and purpose.
Using them, you can use cold forging (bends, kinks, twists) to create anything you want with a metal rod, fittings, strip, pipe, and produce various decorative items.
In particular, through artistic forging you can make:
- Fences;
- Decorate living spaces with fancy ornaments;
- Apply twisted patterns to the gate;
- Protect stairs and balconies with metal ligature;
- Make backs and armrests for chairs, armchairs, garden benches;
- Decorate gazebos and street lights;
- Make various gratings.
To easily do all of the above, in most cases it is enough manual machine for forging, which is quite easy to make with your own hands.
Classification
To work with metal you need equipment. Also, for the manufacture of certain products with a rather complex configuration through cold forging, various drawings and measuring instruments quality control.
No problems if you have everything the necessary tool can be made the following types machines:
- "Snail";
- Torsion bar machine;
- "Gnutik";
- "Wave";
- Press.
Let's briefly look at the features of each machine and the assembly features.
"Snail"
This machine is designed for bending reinforcement, pipes, strips and other metal workpieces in the form of a spiral. During the manufacturing process, it is enough to have an idea of how the device works in order to design it correctly.
During the installation process, you should pay attention to the following points:
The supporting frame (table) on which the workpieces will be bent must be made of metal (channel, thick-walled pipe, corner), but not wood. Since most of the load will be placed on it during operation, it must be durable and not fall apart at one point!
Tabletop. Cut from metal sheet 4 mm or more thick, has round shape. On top of it, the same snail with all the segments is cut out and laid, on which the blanks will be bent.
It is worth noting that you should not save on the thickness of the tabletop. It bears all the dynamic load. The thicker the sheet of metal from which it will be cut, the better.
Main articulated shaft. It is made from pipes with fairly thick walls. Placed along the central axis between two tabletops. Attached to the base with four rectangular corners (triangles).
Lever with roller. It is attached to the shaft, carrying out rotational movements around it during the process of bending the metal.
This is the simplest version of a do-it-yourself cold forging machine, accessible for installation without much effort. If you need to make more complex products, it will have to be modified.
Torsion bar machine
Designed for twisting loose parts. Has the following assemblies:
- Frame (base, support frame);
- Movable and static clamps (vise);
- Handle for turning (twisting). The longer it is, the less effort you need to make. On the other hand, nothing prevents you from connecting an electric motor to the movable clamp, so as not to twist the metal by hand!
"Gnutik"
Designed to bend the workpiece at a certain angle (usually straight or sharp). Its design is simple:
- Tool steel plate;
- Movable stop (wedge);
- Support shafts (2 pcs.);
- Lever arm
In order to understand how to assemble it correctly, you can look at the photos that show various machines for cold forging and the features of their installation yourself, or a video that is freely available on the Internet.
"Wave"
The machine allows, due to controlled shafts (disks), to perform various zigzag and sinusoidal bends (it all depends on the design).
As in the previous design, there are static and moving parts. One disk rotates along an axis around the other due to a lever (knob). When the distance between them changes, a wave of one configuration or another is obtained.
Press
Its task is to form the tips (“leaf” and “crow’s foot”). Essentially, it flattens the end of the workpiece, giving it one shape or another. The most complex of the designs, components for which (especially the firing pin) will have to be purchased separately.
Sometimes it makes more sense to purchase the entire machine rather than assemble it in parts. But this is easier and more financially profitable for everyone.
Artistic cold forging is an art. Basically, it acquired a purely decorative color, without losing practicality and expediency. You can make amazing things from metal rods, fittings and other materials.
The main thing is to purchase or make with your own hands all the necessary machines and equipment to make your dreams of beauty come true.
DIY cold forging photo
Hot forging has been known to man since he began to process and use metals in his life. Before the invention of stamping and metal-cutting machines, hot forging and casting were the only ways to produce tools and weapons, household items and jewelry.
To master traditional blacksmithing, one had to study and gain experience for a long time. The blacksmith's products turned out to be very labor-intensive and unique, this is an undoubted advantage for artistic creativity and an equally obvious disadvantage where it is necessary a large number of identical products.
Disadvantages of hot forging such as:
- high labor intensity,
- high requirements for the qualifications of the master,
- low repeatability of products.
The cold forging method has no disadvantages. It is based on the property of metals to change their shape within certain limits under the influence of mechanical force. The technology is applicable to round and square bars, metal strip, pipes and rolled products of various profiles. Several basic operations such as
- bending the workpiece at a given angle and along a given radius,
- formation of curls and spirals,
- twisting one or more workpieces along the longitudinal axis
and the combination of the resulting parts allows you to create lace fences, gazebos, benches, decorative elements and household utensils in a reasonable time and at an affordable price, several times, or even tens of times lower than when using hot forging.
In addition, all elements will be exactly the same in shape and size, which is especially important when forming patterns and ornaments from them.
To obtain the main elements, special machines are used.
- Gnutik is one of the most popular. It allows you to bend a rod at a given angle and along a given radius, including in the form of a wave.
- The snail is used to twist the end of a rod or pipe into a spiral
- The torsion bar is designed to twist the rod along its longitudinal axis.
Device "Gnutik"
The rollers on the fixed stops are made replaceable in order to be able to bend rods and pipes under different angles and radii. A replaceable roller or wedge is also attached to the movable stop, depending on the required bending shape.
While the workpiece is still straight, it is clamped with fixed stops and, by rotating the drive of the worm mechanism of the bending rod, a movable stop - a wedge or a roller - is brought to it. Continuing to rotate the drive, bend the workpiece to the desired angle.
It is quite possible to make a bend for cold forging with your own hands; it is enough to follow the drawing exactly, observing the dimensions and allowances.
Difficulties in the home workshop can arise with milling high-strength steel and drilling holes in it.
If the workshop does not yet have such equipment, it is better to place an order for the main parts of the bending machine in production - such work will not be completed with a drill and jigsaw.
Connecting and painting parts
To assemble parts into the desired design, it is necessary to provide a flat, free space - on the floor or on the table, depending on the size. It is better to sandblast the workpieces to remove possible rust and clean the surface before welding and painting. You can also make a sandblasting unit yourself from a used gas cylinder, a pair of pipes and taps. For the injector, you can use a ceramic body from a used spark plug. To do this, it is enough to have the skills of welding and metalwork.
After sandblasting the parts are laid out on the assembly site. For ease of work, you can use lining bars. After the parts are placed, it is worth checking again that their location matches the drawing. Next, fixing key elements structures with clamps, spot welding you need to grab them together. Checking the dimensions, angles and mutual arrangement, you can start welding all the necessary seams.
After welding, it is necessary to clean off the scale with wire brushes mounted in a drill, and in hard to reach places and manually. The structure is ready for painting. Depending on the selected primers and finishing paint, as well as on the method of application, the assembly is laid on spacer bars or secured vertically with temporary stops.
Designs with high density It is convenient to paint parts with a spray gun; for rare grilles, you will have to arm yourself with a brush to reduce paint loss.
Products produced by cold forging
A wide variety of products are made using the cold forging method. These are, first of all, elements of gratings and fences - both the rods themselves and the crossbars, tops, and decorations. From a distance of several meters it is difficult to distinguish it from a forged lattice. Any lattice will be enlivened by curls and spirals that form intricate patterns and ornaments. Regular fence Thus, in addition to its utilitarian purpose, it also acquires artistic value. For this you will need a bend, a snail and a torsion bar.
Look great on local area forged stands for lanterns, railings for bridges across ponds, awnings and porches, tables and benches. And it’s a good idea to make the gazebo itself from a forged rod. Curls and spirals will give it unexpected lightness and airiness for harsh metal, and twisted supports will emphasize the upward desire.
Forged barbecues are also widespread today, also complementing the economic purpose with an aesthetic impression. The barbecue itself is lost among the canopy, patterned walls and supports, and the roof decorated with curls.
Parts of balustrades, staircase railings and balconies are also very popular. Curls and spirals are also widely used here, not only as decoration, but also as a structural element. A baluster twisted along the longitudinal axis looks very appropriate, and corner supports are often made from several rods twisted together. They also make the so-called on a torsion bar machine. “flashlight” - several rods bent in a spiral, connected at the ends by welding.
The next area of application of cold forging is details of room decoration and furniture. Door handles and latches, fireplace tools and hangers, umbrella stands and cornices for curtains and curtains - small curls and twisted rods are widely used here.
Furniture is made both for garden furniture, which is not afraid of precipitation and changing seasons, and for home furniture, combining metal with wood and fabric.
