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DIY cold forging molds. Do-it-yourself cold forging: machine, drawings, process. What is cold forging and where is it used?

The “Snail” machine for cold forging with your own hands is used by most craftsmen when working on original rolled products. The blacksmith business is most often based on making forged products, where there are details in the form of original hinges.

It is impossible to imagine an entrance gate in the style of the 17th-19th centuries without curls, monograms and other original elements. They not only decorate, skilled craftsmen could create written greetings from metal. Complex curved pieces are used as reinforcements on fences, entrance groups, railings and other decorative items. Complex profiles add delicacy to structures.

Devices for bending metal elements “Snail”

To bend workpieces according to certain parameters, auxiliary conductors are used, called “Snail”. They serve as a special template that allows you to reproduce dozens and, if necessary, hundreds of similar parts. The “Snail” machine for cold forging bends parts without additional heating.

The work is based on the deformation of metal according to a certain principle. To bend, you have to put in a lot of effort. Therefore, craftsmen quite often equip “Snail” devices with an electric drive. Geared motors help to develop significant forces with a limited shoulder of force application. The torque in the processing zone can reach several tens of kilograms.

If you do similar work Only due to the physical strength of the blacksmith, the worker will get tired quite quickly. Its productivity will drop to zero. And with a mechanical assistant, hundreds of workpieces can be produced per shift.

It must be taken into account that bending of workpieces is an intermediate stage in the manufacture of complex structures. They still need to be installed in in the right place and weld. Only then will an intermediate result be obtained. Then the product will need to be painted and installed at the place of order. All operations will require not only time, but also the physical strength of the master.

Structurally, the device can be:

Non-separable, then it will be used to bend parts only to certain lengths. The resulting spiral has certain limitations in use.
Prefabricated (there are additional fragments to increase the bending time), and the device can be used to bend long parts. Large sized parts will be received.

For working with parts from profile pipe small rooms some make hand-made devices. They involve the use of levers to help move the workpiece around the mandrel. The finished parts are removed from the end, slightly loosening the tension.

Most often in such cases I use square bars □8...12. Some craftsmen manually bend profile pipes 15·15 mm with a wall of 1.5 mm. For larger products, a mechanical drive is required.

Manufacturing technology of the “Snail” device

Simplified technological process making a “Snail” machine with your own hands can be represented as a series of sequential operations.

A profile of the product to be manufactured is drawn on a sheet of paper. When drawing, the dimensions of the product are maintained. The drawing is needed only to obtain the profile of the part itself. Attention! When processing, the thickness of the workpiece is taken into account. A gap of at least 3...4 mm is needed, then the product can be removed after bending it in the device.
For most machines, a central stop is made. It will record the beginning.
Various masters They use their own fixation techniques, so their products can be distinguished by their handwriting.
A support plate is cut from a steel sheet. The center will be welded to it, as well as the spiral. The thickness of the plate must be at least 3 mm, since significant forces will be applied. The size of the plate in the future will also determine the parameters of the curl.
Using the spiral drawing, the workpiece is bent from the strip. When bending it, the parameters are controlled. The more accurately this element is manufactured, the easier it will be to manufacture elements for forging products. Attention! If it is necessary to make curls with more than one turn, you need to cut the spiral strip diagonally. Therefore, a strip of much wider width is used. The minimum size corresponds to the height of the profile that is going to be bent on the machine.
The device is placed on a special rack to make it easier to form finished products. For small parts it is convenient to place them on a vertical stand.
To make the job easier, weld the handle. It is installed on the reverse side so that it does not interfere with the installation and removal of workpieces.

Step-by-step manufacturing of a small-sized manual machine for making curls

A small machine is designed for the production of curls from rolled strip with a width of 20...30 mm. It's easy to make it yourself.

First the center is made. To do this, a small fragment of round timber is sawed off. The workpiece is fixed in a vice and the cutting line is marked. Using a cutting disc and an angle grinder, the workpiece is sawed off.

It has a diameter of 38 mm. The side surface is not further processed.

The center length is 28 mm. A little more is possible, but this is enough to bend a strip 30 mm wide.

On drilling machine a hole Ø 8 mm is drilled. It is placed eccentrically. This situation is due to the fact that it is necessary to make a clamp for the end of the workpiece.

A profile is drawn, which should be removed using cutting and cleaning discs installed on the grinder. The workpiece is secured in a vice and excess metal is removed.

Petal discs protect the surface so that there is a smooth transition between different surfaces retainer.

To make it easier to fix the end of the workpiece in the future, you need to drill a hole. It is placed on the radial surface of the center. A hole is drilled for an M10 thread.

Using a set of taps, the internal thread is cut. A headless screw will be used here. After fixing the workpiece, it will hide inside the metal of the center.

The center is welded to the 4 mm thick base plate. This completes the work of its production.

Making a fixture

To make it easier to work with the device, a shaft is welded to the back side of the plate. By rotating it in a special mandrel, the snail will rotate.

The outer surface must be ground so that the welds do not interfere with the free fit of future workpieces.

The future spiral is drawn on the plate. A contour is created where it will be welded later.

A spiral is bent from a strip 4 mm thick. It must correspond to the project.

After checking the spiral against the template, the excess is cut off, and the spiral itself is welded to the plate and to the center.

A 40×40 mm profile pipe with a 3 mm wall is used as a stand. Holes are drilled on it for attaching machine elements. Using support platforms, the prepared parts are fixed.

The handle is visible on the reverse side. It was secured to the shaft using a bearing. The prepared “Snail” can rotate.

A performance check is being carried out. Using the handle, the spiral is rotated around the center axis.

Making a simple part on a machine

The strip steel workpiece is cut to the required size. This size is usually clarified by drawing the finished product and its component elements.

The free end is placed in the center of the spiral. The workpiece is secured using an internal screw.

The “Snail” rotation is performed. The workpiece is pressed tightly against the guides. This requires some effort to obtain the desired product profile.

Usually the other end does not stay straight. It is also bent. Therefore, a distinction is made between internal and external reverse curls. Marks are made on the device itself using a marker or chalk. They are used as a guide when making curls with the required parameters.

As can be seen from step by step guide Using a simple set of tools, a homemade curl making machine is easy to make. How much does it cost? Its price is determined by the cost of the blanks. Often the price is minimal.

How to bend a profile pipe on the “Snail” machine?

If you try to bend a profile pipe without special preparation, the weld will come apart. It will be a marriage.

Blacksmiths with extensive experience make more complex machines to make their products. They additionally equip the “Snail” with removable elements.

Step-by-step technological process for making a reverse curl on the “Snail” machine

The rolling rollers perform sequential crimping of the pipe. Protruding ribs are formed, and the weld remains inside the layer, offset to the center.

The pipe ends are compressed on parallel eccentric rollers. It becomes like a stripe. In this form it is easier to fix it on the machine.

The shank is formed in a special device. Now the workpieces will be fixed on the machine in one movement.

The workpiece is fixed in the center. There is a groove that secures the shank. It can be seen that the spiral has a uniform descent in height.

After fixing the shank, the electric motor is turned on. Forming of the part begins.

The loop is formed when the workpiece touches a special support element. It is more often called the support shaft. To reduce the force, it is equipped with a bearing. The part rotates freely around the support.

Part of the spiral is formed. But if it is necessary to process for a longer length, a removable element will be installed.

A blank is also formed from the other end. Here the master determines in which direction to bend the part.

To continue work, a removable element of the “Snail” assembly is installed.

Now you can form the bend of large parts.

Even long workpieces are easily bent to specified dimensions. Marks are made on the work items. They are used to guide how much to bend.

On the reverse side, additional bending of the part is performed.

The product is being finalized on both sides.

The finished part has a finished appearance. If necessary, the shanks will be sawed off. Then no one will guess how the workpieces were fixed.

If you need to make a small part, then use another “Snail”. Experienced craftsmen have several of them.

Examples of products with curls

Original canopy over the entrance to the building:

When decorating a French balcony, original curls give an openwork look to the entire product.

On a flight of stairs, the curls look very original.

Using only curls, they make supports for the bench, and also create a grate for the fireplace in the same style.

On spiral staircase the hand of an excellent craftsman is visible. Not everyone will be able to make such a product.

The gate leaf contains elements made on the “Snail” machine. The heavy product has acquired a special lightness.

Light staircase in high-tech style. She can decorate not only Vacation home. Modern palaces with minimalist design can have an excellent appearance.

The scope for creativity is unlimited. Many blacksmiths are true artists. They decorate the world around them.

Video: “Snail” – do-it-yourself cold forging.

Conclusion

The cold forging method, which uses Snail machines, allows you to produce original curls.
You can make a simple machine with your own hands. It can be used to produce professional blanks.
A complex machine with removable elements will allow the production of large spatial parts.
The use of curls in the manufacture of blacksmith's products opens up wide possibilities for creativity.

Looking at the fences, gates, gates of various cottages, a person who has no idea about blacksmith tools or work in a forge asks: where does this money come from? A person who understands blacksmithing will answer him that such things (metal furniture decorations, swings, benches) are made using devices for cold forging.

The cost of cold forging is not too high. This is due to low equipment costs and high processing efficiency. A blacksmith who does this type of work can quickly start making a good profit. Probably, some cottage owners make all the fences and gates themselves, because cold forging can be done in a garage or barn without having any special skills.

The main thing you will need is homemade equipment for cold forging. If you want to make various objects from metal, you will need five to seven types of equipment. You can make three to five cold forging machines with your own hands. Before you start crafting, you need to learn the basics of working in a forge.

Stamping, forging, bending

Cold forging differs from stamping in that the material practically does not flow under the influence of the tool. Look at a beer can or, for example, an aluminum/tin teapot. Their extrusion is carried out in 1 blow of the stamping device.

Cold forging differs from hot forging in that the part is not heated before processing. The workpiece is, as it were, riveted by hitting it many times. The metal structure changes significantly. The surface strength increases, and the middle becomes more viscous. Handicraftsmen really value tires for carriage wheels and parts of rails.

The metal is riveted using a conventional hammer. Making it yourself is easier than making a homemade cold forging machine. However, such forging still differs from cold hardening. When it is performed, the metal structure does not change much.

Currently there are different kinds machines for cold forging. An electric drive is rarely used, because the increase in efficiency it causes often does not justify the difficulty of creating it and the expense of electricity. For cold forging, machines are divided into:

twisters - form flat spirals and other curls with a narrow middle;
torsion bars - make it possible to create a screw twist of a rod and parts from volumetric spirals (filaments);
stamping-inertial - with their help they perform splashing of shaped tips, stamping of decorative clamps to combine patterned parts, extrusion of relief elements on long products;
bending – processing is carried out by pressing, drawing or a combination of these methods. In the first case, waves and zigzags are made, in the second - rings and curls.

In various books, especially English ones, all homemade machines for cold forging with your own hands, which form products by twisting/curling, are often called twisters. Initially, the twister was used to wind springs. However, it is more correct to believe that a twister is a winding device, and a torsion bar machine is a torsion device.

Gnutiki

In a do-it-yourself cold forging machine, a bender is a device designed to produce zigzag elements. By replacing the roller/wedge, it is possible to change the zigzag angle within a certain range.

A bend for pipes and rods up to sixteen millimeters is cheap. It is difficult to make it at home, because it requires spot processing. Try ordinary electric drill make a hole in the wrench. But the load in the bend is much greater. In view of this, it is easier to purchase a flex. It can be used both for forging with your own hands and for the production of welded parts metal structures, bending small pipes.

Twisters

Since ancient times, blacksmiths have made curls according to a mandrel template using a horn gripper-lever. This method is ineffective, but it makes it possible to create various bending mandrels from an ordinary metal strip without much difficulty and a lot of time. The persistent lever horn does not allow the template to move under the pressure of the part. The horn must be sliding and fixed. Processing will proceed more slowly, but with greater accuracy.

Another homemade device for shaped bending it is a strong board with support pins. They can serve as ordinary bolts. It is possible to process a strip of up to six millimeters. It all depends on your physical strength. Bend the strip “by eye”. The process is quite slow, but it is possible to create a wide variety of patterns.

Snails

One of the types of twister (forging machine) is a snail. It is very common among people who do artistic forging. The snail has a simple design and can be created at home. In addition, it is easy to use and multifunctional. The snail machine is ideal for forging. It consists of a bending lever, which is slightly improved and mechanized. This equipment for cold forging of metal is divided into 2 types.

With ploughshare

The operating diagram of this device for cold forging is as follows:

The snail turns.
The workpiece is fixed on the device.
The roller is pressed against the part by means of a spring.
The cochlea is rotated clockwise (levers are used).
The fixation is removed, the cochlea rises, and the finished curl is taken out of the device.

The advantages of such a twister are:

It is possible to process parts without special equipment. This is due to the fact that the vertical load on the floor of the room is quite small.
The support is quite simple to make; you can weld it from ordinary metal profiles.
It is possible to work alone. Turn the collar with one hand and press the strip against the ploughshare with the other.
It is possible to make spirals with five turns.

Lever

Similar manual machines for cold forging have a design similar to a pipe bender. They are less efficient than gated devices. The load is quite large. Because of this, a strong base made of special steel is required. After turning the lever until it jams, you need to move the pressure roller. You can create up to four curls on a snail. This manual do-it-yourself cold forging machine has the following features:

All elements, with the exception of the pressure roller, can be made of ordinary steel.
The pressure roller can be a standard roller bearing.
The machine base can last more than a thousand work cycles.
Bending can be done either using a template or using spacers.
It is possible to quickly change the shape of the manufactured product and make reverse folds.
The end of the workpiece can be fixed by placing it in a template recess. Widening is carried out by welding or bending.

Torsion bars

This cold forging tool makes it possible to increase efficiency and increase the quality of manufactured products. The working force is quite large, therefore a high-strength base is required. A backbone I-beam frame of one hundred millimeters or a pair of connected channels is suitable. The base must be securely fixed to the supporting surface by means of the paws attached to it.

The part (a square-shaped rod) is fixed with chucks and mandrels with sockets. Due to the fact that the rod decreases in length when twisted, the chucks in the spindle element and tailstock must be well secured with screw clamps. The tailstock must be sliding.

If the device is needed to make, for example, a small fence, then you can make a cold forging machine with your own hands from scrap or improvised means.

Electric drive

Working on a torsion bar with a non-electric drive is tedious. Good quality almost impossible to achieve. This is due to the fact that it is difficult to achieve a uniform torque manually. In view of this, it is better to use an electric drive, which must be installed in the forging tool. The drive can be made from available means (axle drive axle of a rear-wheel drive car, gear differential pair). The engine is 1.5-3 kW, 900 rpm. You can familiarize yourself with other options by watching the corresponding videos on the Internet.

Wave and zigzag

How to make a cold forging machine, through which it is possible to create wave and zigzag elements? To do this, you will need rollers made of tool/chromium-nickel steel. Limiters are placed in the arc, making it possible to create an accurate wave profile.

If you install a special gate on the snail, you can create waves. The handles are the same. They are screwed into the threaded sockets on the gate head. It is recommended to place the main roller separately and attach it to the base with head bolts.

Forged products must be combined into one whole. The easiest way is to weld and then smooth the seams with a grinder and a grinding wheel. It is thicker than cut-off and copes with bending forces. Parts that are connected with shaped clamps look much better. Stamping is carried out from a strip of one and a half millimeters. The clamp blank is made in the shape of the letter “P”. Her wings bend with back side by means of a hammer. For painting, special enamels and paints for metal products are used. Enamels with pigment are more expensive, but they are not prone to peeling, fading, wear and thermal deformation.

The loads endured by a cold forging press, especially impact loads, are quite high. This requires precise processing of the workpieces. In view of this, it is better not to try to make such a device using a drawing of a cold forging machine. You can only make a manual rolling mill yourself. However, steel rolls, shafts and bearing bushings will still need to be purchased.

If you seriously intend to take up blacksmithing, try making a twister or torsion device. The drawings of a cold forging machine are quite simple; even a person who is very vaguely familiar with blacksmithing can understand them. You can find machine drawings on the Internet or ask friends who are involved in blacksmithing. Of course, the profession of “blacksmith” today is less popular than the same “conductor”, but this does not mean that no one is engaged in blacksmithing at all.

The private sector of any city is characterized by a variety of elegant metal products. This is a metal patterned gate, beautiful benches, unusual railings and others decorative ornaments. Forged products add a certain aesthetics to the appearance of the site and the house. Many people believe that using forged metal fixtures is very expensive. But this is not always the case.

Such products are made using the cold forging method. If you buy them in a store, then, of course, you can shell out a considerable amount. That's why experienced craftsmen make a cold forging machine with your own hands. Moreover, if a person likes to do something on his own, then this device will be useful on the farm.

And also, by doing artistic forging, you can make good money. After all, production waste and initial setup costs are small. Therefore, the business of a blacksmith engaged in cold forging can quickly go uphill. Forging may be carried out in a garage or shed. Accordingly, renting premises is not required.

Cold forging concept

The cold forging procedure differs from the hot forging process in the simplicity and safety of the process. The metal is not exposed to high temperatures. Compared to stamping, this process involves almost complete elimination of metal flow. If we consider cold forging, from the point of view of the forging process itself, then this is the process of riveting elements using impact force.

As a result, the strength of the outer layer increases, and the inner part imparts overall toughness and fracture strength. Of course, the forging procedure itself is very lengthy. Therefore, it is worth talking in more detail about a certain branch of cold forging called artistic forging.

It is also essentially cold forging, and henceforth the term “cold forging” will be used. It consists of various bending of metal sources. The structure of the metal base does not change. Physical and mechanical properties also do not change.

Cold forging involves the formation of a variety of twisted elements and bends. Such patterned elements are made on a specific installation. Moreover, the drive of these installations is divided into manual and electric. For large volumes of work, it is preferable to use machines with an electric drive to increase the speed of execution.

Manual settings can be used to produce the following decorative items:

Designs for windows.
Components for making railings.
Chairs, benches.
Furniture legs.
Decorative items for gates and wickets.
Parts for fireplaces.

As for the starting material used for forging, they are used different types: aluminum, copper. You can also use alloys - duralumin, steel, brass, magnesium alloy, nickel alloy.

Advantages of the method

When compared with other methods of producing metal products, cold forging has a number of advantages. These include:

Heating of the metal is not necessary, which simplifies the manufacturing process due to the absence of a furnace and maintaining a certain temperature.
Process safety.
Ease of production of cold forging installations.
The ability to correct a manufactured product due to its mechanical properties.
The ability to manufacture equipment for the production of identical products with standard steps.
Saving time and money when performing work.

The presence of these advantages makes cold forging technology widespread.

Equipment types

There are many types of cold forging machines. The following categories are established:

Gnutik - helps to obtain metal arcs that bend at a precise angle.
Snail - a device that allows you to form a spiral from rods.
Twister – allows you to obtain a more complex spiral formation along the axis.
The ring is a bending mechanism for making ring and oval shapes.
Wave - the installation is intended for bending rods into a wave.
Press - allows you to carry out the process of flattening an object.
The hammer and the anvil are tools that help correct mistakes.

Making a cold forging machine for each of the listed categories with your own hands is quite easy. Only some tools and metal material are required. Especially Money almost no need.

Manufacturing a mechanism for cold forging

A universal cold forging machine is almost impossible to make with your own hands. It is necessary to make a separate form of mechanism for releasing objects.

When manufacturing the installation, it is necessary to select the following materials:

metal sheet (preferred thickness 4-5 mm);
reinforcing bars, profile pipes;
bed for stability of the device for cold forging;
electric motor and gearbox in the case of a machine with a drive.

Of course, making fixtures cannot be done without tools. It is advisable to have an angle grinder or a metal file, a welding machine, an emery stone or paper, a vice and pliers, as well as a pencil, tape measure and paper.

The easiest way for a novice craftsman is to make a homemade machine for cold forging the shape of a snail. Thanks to it, various forms of metal rods for gates and fences are produced. The torsion bar type of installation is also popular. Other forms of machines can be made after gaining experience with simple setups.

Let us examine in detail the production of the “snail”. This device helps to obtain a variety of configurations of spirals, curls, and rings. Simple design this equipment contributes comfortable work and easy access to the workpiece. The process can be carried out if:

Metal rods.
Steel leaves and stripes.
Profile pipes.
Welding machine.
Angle grinder and pliers.

To make homemade machines used during cold forging, it is advisable to draw a diagram or sketch of the future device. Initially, graph paper is selected for drawing the drawing.

The following stages of work:

An image of a spiral with three turns is applied to a sheet of paper. The dimensions must correspond to the diameter of the reinforced rod with the condition that it fits into the thread. The best size to use is 10mm. And also the lines should be drawn based on the thickness of the steel, and the distance inside the spiral should be 12-13 mm.
Next, you need to use a steel grinder to make a circle of the required diameter. If you want to use removable circles, you should take something that is not thin raw material(4-5 mm thick) for easier changing.
Making a durable frame that is stable on the floor surface. You can, in general, concrete the legs for more robust construction. An important condition is that the frame circumference must be larger than the dimensions of the working circle.
Welded to the frame metal rod, onto which the bearing device is mounted. Manual control involves welding the circle to the frame. In this situation, metal bending occurs much easier than during the rotation process.
We fix the snail on the circle. The snail is divided into three parts. The tail part has a height of 1 cm based on the thickness of the rods. 1 cm is added to the next part of the spiral. This means that the second turn will be 2 cm, and the third - 3 cm. When obtaining more turns, the details of the spiral should be increased.
If it is necessary to make replacement circles, then the replacement parts are welded to the circle according to the sketch.
If you have a replacement volute, you need to measure the position of each type and weld the studs to each element. In this case, a gap is made in the circle for a certain part.
To get a forged product, you need to start with the central coil. It is necessary to firmly secure the rod using a vice or other tool.
At the end you need to make a lever from two profile pipes (diameter 15-20 mm). They are welded with jumpers, the length of which is the distance from the center of the bearing to the top point of the circle plus 5 cm. Next, it is welded to the bearing part. A rod with a length corresponding to the length of the tallest part of the snail is welded to the lower part of the lever, which is the cut round part. A bending barrel is welded perpendicular to the area of the circle.

Thus, the homemade machine is ready. You can begin producing the necessary elements. To do this, the rod is fixed, and then the barrel rests on it, and the bending process begins.

Video: DIY cold forging machine.

Torsion bar machine

Another popular device, such as a do-it-yourself cold forging machine, is a torsion bar. It is used for forging snake-shaped spirals. To make the installation you will need:

Sheet of steel.
I-beam.
Vise.
Parts for fastening.
Angle grinder.
Welding.
Gearbox and electric motor.

To make this installation yourself, you need to go through certain steps:

First you need a beam, a sheet of steel is welded to one part of it.
Next, a vice is welded to the steel, which then needs to be secured with bolts and nuts.
Plates are attached to the vice to reduce the risk of the object jumping out when tensioned.
On the other part of the beam, rollers are installed to secure the platform. Moreover, the device with rollers must be at the same height as the design of the vice.
A vice with movable parts is placed on the completed installation.
A steel handle is attached to perform rotation. As a result, the workpiece will bend.
Next, the electric motor is connected, and the entire system is covered with a steel casing.

Thus, the structure made is a machine with a movable and fixed block. This method of manufacturing a machine is quite simple, but requires some effort in operation.

Many people who are interested in metal decorative items are faced with the question of how to make a cold forging machine with their own hands. Having studied this issue in detail, you can, without experience and a workshop, produce various metal products for landscape purposes.

The machine is quite simple to make using tools and materials that almost everyone has. Moreover, your equipment can be adapted to any type of product.

Forged fences, fencing, garden furniture– expensive exterior items, and with the help homemade equipment and skills, you can make metal structures with your own hands, even for sale. In the article we will tell you how to make a simple manual machine for cold forging of metal with your own hands, and also provide drawings.

Types of machines

Depending on the technology used and the result obtained, as well as in connection with the resources expended on working with the workpiece and the capabilities and functions of the device, all of them can be divided into categories. Some can be made at home, others only in factories.

Machine "Snail"

The body itself consists of a spiral into which a metal profile or metal cord is placed. The product has several segments, the more of them, the stronger the twisting occurs. It’s great when you can exchange some fragments for others in order to change the radius of the resulting bend, then one device can be used to perform different tasks.

Briefly about the main components of the device:

Frame - it is created from durable metal channels, corners or pipes.
The bed has a rounded surface - a large load is placed on it, so it is necessary to make it as strong as possible.
Shaft made of thick-walled pipe for rotation.
A lever that is attached to a cylindrical roller in the middle.
The segments of the cochlea themselves. They can be pre-drawn directly on the tabletop, measured, and then made from steel, or you can use cardboard templates and then make them from a metal sheet.

DIY torsion equipment for cold forging

Using such a machine, you can get not curls, but fragments of metal profiles beautifully twisted around their axis. Pipes and round rods cannot be subjected to such bending, but hollow and solid metal products with a square cross-section look very elegant with a twisted pattern.

The device for longitudinal twisting consists of a frame (of channels or I-beams) with a firmly installed clamp. A stationary section of the workpiece will be secured in a vice. At the second end, the movable one, there are rollers that set this section in motion. The tip of the metal profile is also clamped in the clamp. Long handles come from the tip (the longer the lever, the greater the force applied) - they set the apparatus in motion.

Machine "Gnutik"

The device resembles a stamping or press, since only one part is active, and the bottom with fastening remains passive. Two shafts are mounted on a stationary frame; they hold the workpiece (pipe, metal profile). The moving element - the wedge - is initially located at the bottom, but when the part is placed between the supports and the lever, the latter begins to move and “pushes” the plane. The result is a zigzag, or “bend”, as in the photo:

Machine "Volna"

Often such devices are not made independently, but purchased. They are universal and suitable for making bends with different radii. The design of homemade equipment for cold forging consists of a tabletop with two disks of different or equal sizes, one supporting and the other movable. A crank is attached to it, with the help of which the entire system is set in motion.

The peculiarity is that you can move the arrangement of elements, as well as change the circles to a different diameter - this allows you to change the bending radius.

Press machine

This device allows you to make flattened tips of hexagons, rods, and metal profiles. It consists of two shafts firmly attached to each other - there is a minimum gap between them. They can be completely smooth or grooved. In the first case, you will get a classic flat peak, in the second - a “crow’s foot” with corrugation.

It is necessary to insert the workpiece into the slot between the two rollers, then move the device using the lever, then back. The movement is strong enough and fast enough to produce a rental. This is what the result of the process looks like:

Differences in cold forging

The main difference in the procedure is that there is no additional heat treatment, that is, heating. Deformations are carried out under normal temperature conditions for steel.

Peculiarities:

simple equipment that you can make yourself;
there is no need for a stove or other equipment for blacksmithing;
it is necessary to use physical force, but the equipment can be equipped with an electric drive;
aesthetic appearance and leaving all technical qualities and properties.

Construction of cold forging machines

Depending on the variety, the design varies, but there are common features:

strong frame - it must withstand the weight of the workpiece plus the force with which the lever rotates;
all elements are made of reliable steel - wooden templates are too soft to bend hard metal on them, but aluminum or thin-walled steel sheet - why not;
This is usually a stationary device.

Rest design features depend on the species.

Equipping a torsion bar cold forging machine with an electric drive

Electrification is a pointless exercise and costly if you need to bend one or two workpieces. But if you intend to make curved elements for an entire fence or do this professionally, then you cannot do without the help of an electric motor. What does it give:

increase in speed;
the efficiency and productivity of the unit as a whole also increases;
stable and gradual work;
reliable fixation, lack of influence of the human factor (various types of errors when turning the lever);
the employee is significantly less tired.

If you are planning a multi-batch production, you need to supply a motor and belts to transmit power to mechanical movement, but calculations must be made first.

Building a curl for the machine with your own hands

This section is relevant for those who make “snail”. The most convenient way is to draw a logarithmic spiral on the tabletop, make it at the turning points of fastening in order to divide the entire curved line into removable parts. Then we recommend making templates from paper/cardboard and then transferring them to steel.

The main difficulty lies in the calculations. The radius from the center to the extreme point is constantly increasing and growing depending on the number of turns and the desired bend. We have given an example of a drawing with dimensions already applied, but you can calculate them for yourself:

Construction of a cold forging machine

make several holes for fastenings - this way, if necessary, you can move one of the elements (shaft, part of the volute, etc.);
prepare removable parts of other sizes, for example, circles of larger and smaller radius.

It is most convenient to fasten the nozzles using bolts.

How to build a curl

When you start manufacturing, you will understand that each individual product needs its own template with unique parameters. Therefore, we recommend making several blanks with standard dimensions, and then installing them on the frame depending on your needs.

The main apparatus that is used is the “snail”, everything here is built on a logarithmic spiral. The radius of each turn during a turn is greater than at the previous point.

Snail with lever

We talked a lot about this device, let's see how to use it:

Torsion bars

Helical twisting of rods is possible without any machine equipment at all. How to do this: if the rod is placed inside the pipe, and one end is clamped in a vice, then you can simply start rotating at the base of the second fixed edge using the handle. The constrained space will not allow the workpiece to make involuntary bends, since all the turns will be the same. But, it is not convenient to carry out the procedure in weight; it is much better if all the structural elements have their static position on a strong tabletop. And it’s even better if you don’t have to turn the turntable with your hands, but only press a button.

About the electric torsion bar drive

Wave and zigzag

If you do not need curls and circles, but only small bends - wavy or zigzag, sharper, then you will need a “bend”. We have already talked about its equipment. Now let's explain that the operating elements (there are three of them - two static, one movable) can be replaced. So round shafts for a soft wave can be replaced with wedges with sharp corners, which gives an even and clear zigzag.

Assembling the device

We recommend that all elements at the preliminary stage be connected to not very strong fasteners (you do not need to work with welding right away), since errors could have been made during the design. Start with the bolts and then do a test run. If you are completely satisfied with the design, then you can make the final assembly with the strongest connections, including using a welding machine.

Connecting and painting parts

The inside of the snail, which is in constant contact with the workpieces, should not be painted, but only carefully polished - without snags and rust. The remaining parts can be coated with any paintwork.

How to get around a stone

So, the question is – do it yourself or buy ready-made equipment? If you need high performance and accuracy, then it is better to order a factory unit. In the case when you need to bend one or two blanks, you can make the simplest “bend”.

Products produced by cold forging

There is a lot that can be done, we will list the most common methods of application:

Garden furniture: tables, benches, chairs, trash cans.
Swing.
Fences, fences and decoration of solid gates.
Balcony railings, as well as handrails for stairs and steps. The twisted structures themselves.
Canopies and covered courtyards.
Barns, greenhouses with metal frame, as well as any metal structures where a bent metal profile may be needed.

In the article, we gave drawings of homemade machines for cold forging with our own hands, and talked about their features and differences. To complete the topic, let’s watch another video on how to make full-fledged equipment at home:

Forged products are created using hot and cold processing. The latter method does not require special skills, but its implementation requires special devices. There are various drawings of cold forging machines, many of which are suitable for creating a tool yourself.

Manufacturing Features

Forged metal elements are formed as a result of deformation, and during the work the performance characteristics of the material must be taken into account.

The structure of the metal crystal lattice consists of grains having irregular shape. The tool used for forging affects it and leads to a change in the appearance of the part. Special meaning has a selection of machine drawings, since the workpiece must retain its previous properties.

Homemade cold forging machine: manufacturing rules

There are certain rules, compliance with which ensures obtaining the desired result:

Creating a suitable configuration is possible using several tools.
Before production begins, the parameters of the formed products are calculated.
Rods used for workpieces may have different diameter, which is selected taking into account the degree of complexity of the equipment and subsequent operation.
It can only be processed because other types do not have the necessary plasticity.

"Gnutik"

For cold forging, you can make it yourself, just understand the intricacies of using the tool and select a suitable drawing. "Gnutik" is necessary for creating corners of various configurations. Its main structural elements are a driving stop and two shafts placed on a steel plate.

Homemade cold forging of this type must be created in accordance with certain features. For example, the deformation angle must initially be determined. It is also possible to add an additional bending element; if used, a third rotating shaft is mounted.

The tool is made of special steel, since it bears heavy loads during the process. It is worth noting the possibility of collecting various parts, including wavy ones.

"Twister" and "Snail"

Today, artistic forging is not complete without screw-shaped parts. Their creation is ensured by manual cold forging machines called “Twister”. They have a characteristic feature that consists in scrolling the rod along the axis. The tool consists of a movable and a fixing part. The rotary handle deforms the workpiece, which is fixed between the main parts of the structure. It is worth noting that the spiral is formed from the side of the product fastening, and the applied forces can be reduced with proper calculation of the lever that exerts pressure. This device allows you to produce parts for metal fences and window grilles.

“Snail” is the simplest homemade machine for cold forging, which ensures the formation of spirals with the required number of turns. It is the most popular and can be adapted to produce the desired product. The tool is equipped with a manual or electric drive, the type of which is selected in accordance with the intensity of use.

Homemade cold forging machine: preparation of materials

First you need to draw a spiral with an identical pitch of all turns. In this case, you need to start from the workpieces used, since the stroke width, as a rule, is within 15 mm, while the tool is intended for rods with a cross-section of 10 mm. Free space is necessary for maneuver, since when the workpiece is fully compressed, bending will become impossible.

Next, you need to cut a plate measuring 20x20 cm from a steel sheet. Despite its small dimensions, it will ensure optimal workflow. In accordance with the length of the expected “snail”, a steel cut is made. The strip must be bent using pliers, placed on the plate and outlined with a bright marker on all sides.

Next, a part of the rod is cut off with a length equal to the width of the steel strip. The main thing is that it does not exceed this parameter, as this may cause injury during bending. The rod is necessary to secure the material at the first stage of creating the product in order to prevent free movement at one point.

A part with a length of 10 cm is cut off. It will combine the sheet and the base on which the fixation will be made. Due to the high load, only thick-walled materials should be used. After all the main elements have been prepared, you can assemble a homemade cold forging machine, the drawing of which is presented below.

Assembly of the structure

The steel “snail” is divided into turns, the first of which will hold the workpiece, and the others will contain the turns of the rod themselves. The central part is welded to the base, and the resulting seam should not have even the slightest defect. The pieces of rod are welded to the main part of the strip, the distance between them should be 3 cm. Care must be taken when forming the seams, and then knock them down with a hammer.

Then the strip sections are installed in the required places and outlined with a marker. The resulting circles are needed to form holes. They must perfectly match the diameter of the legs to ensure easy installation and removal.

The final stage is the welding of the profile pipe in the lower part, as well as the fixing element next to the “snail”. Photos of homemade cold forging machines made in a similar way are presented above.