Own business: Cold forging of metal products. Equipment for the production of forged gratings Cold forging production

Architects and designers often use forged elements in their work. Openwork metal grilles covering fireplaces or beautiful balusters on the stairs look elegant and noble.

If you know how to forge and learn this craft, you can create original products yourself.

This activity is suitable for anyone who likes to do physical work and who is ready to get acquainted with the technology and features of choosing a metal.

What you need to know about forging?

Forging is a process of processing a special workpiece. Its purpose is to give the metal the required dimensions and shape. There is a distinction between hot forging and cold forging.

The master needs to get acquainted with both varieties in order to know the advantages and disadvantages of each.

Hot forging method

In the hot method, the metal workpiece is heated strongly. As a result, the metal becomes ductile. Hot forging gives the workpiece the required dimensions and desired shape. The master has a variety of work options available to him.

Heating a metal workpiece also has its disadvantages. First of all, it is necessary to arrange a special room. You will need to buy a forge, for which you will have to buy fuel.

Fire safety rules must be followed; it is important that the master knows how to work with fire.

Having an idea of ​​the temperature conditions used in the forging process, you can easily select the desired type of forging.

Cold forging method

Cold forging is a labor-intensive process. To achieve the desired shape from a metal workpiece, it is bent, pressed and welded. The technique is a little simpler compared to the hot method.

The workshop does not require a lot of space, and to set it up you do not need to purchase a special forge; it is enough to buy a forging machine.

The manufacturing process of a product involves working with semi-finished products. If a mistake has been made, it is impossible to correct it.

Choosing metal

Metals with certain properties are suitable for hand forging. The more ductile the metal, the easier it is to change its shape. However, ductility is inextricably linked with strength.

An increase in one characteristic inevitably entails a decrease in another. When buying a workpiece, the master must know exactly what its composition is.

Craftsmen make decorative forging elements from copper, steel, duralumin or brass. In addition, alloys can also be used. Information about metals that can be easily forged can be found in the Steel and Alloys Guide.

What tools are needed for forging?

Inventory varies depending on the forging method. A forge with an anvil and hammers with tongs will be needed for hot forging.

For the cold method, you need a “Gnutik” tool, which allows you to bend the workpiece at an angle, and a “Snail” machine for forging, which you can make yourself. The latest machine allows you to create decorative elements with a spiral shape.

Note!

In addition to the basic tools for the cold method, “Flashlight”, “Wave”, “Twister”, a ring machine and others can be additionally used.

The modern market offers industrial machines designed to perform technological operations. In the photo of forging you can see a product made on the “Master 2” machine from the MAH company.

Hand forged

In order for the workpiece to acquire the desired shape, the master must use different techniques and methods in his work. You will need to purchase various tools and master different technologies.

The cold forging method does not require much effort from the master. The work includes the following stages:

• creating a drawing or sketching a decorative element;
• procurement of workpieces;
• forging process.

Today, you can make a drawing using a computer program yourself or order it from professionals. The project will allow you to calculate before starting work how much metal blanks you need to purchase.

Note!

The main forged elements are represented by the following groups:

• Paws. The end of the metal rod is given a certain shape.
• Curls. The ends of the rod can be bent in one or two directions.
• Rings. Decorative elements are made from rods with a square or round cross-section.
• Torsion. It is characterized by helical twisting along the axis.

3 generally accepted technologies are used: drawing, bending and twisting.

• The hood allows you to increase the length of the metal workpiece, reducing the value of its cross-section.
• Bending makes it possible to bend any part of the workpiece at an angle.
• Twisting is a technology in which the workpiece is twisted along its axis. A Twister machine is used for twisting.

All elements are assembled together and secured by welding. These operations are performed on a special table. Homemade cold forging does not require any special skills.

DIY forging photo

Note!

Business idea: cold forging of metal products
Where we do business from: garage, territory of a private house
Main costs: purchase of equipment
Necessary equipment: welding machine, cutting machine, vice, drill
Consumables: metal, varnishes, paints
Initial capital: no more than 30,000 rubles.
Payback period: several months
Possible profit: 50,000 rub. per month

A business idea based on cold forging of metal products. This idea can be classified as a business with small financial investments; at the initial stage, you will only need skill and no more than 30,000 rubles.

At the initial stage of organizing this business, it is better for you to learn for yourself all the intricacies of manufacturing cold forged items. To start, you will need a room that can be used as a garage or area near a private house. Also a set of equipment:

1. Welding machine
2. Grinding machine (grinder)
3. Vise
4. Drill, drilling machine
5. Other small instrument

The main skill will be the ability to use a welding machine.

Once you become familiar with cold forging, learn how to make simple items, and perhaps find your first clients, you can purchase an additional set of bending equipment that will help you make complex items. The cost of such a kit is about 55,000 rubles. This kit will help you make complex objects, make bends of the same shape at the same angle, and many other useful things.

Basic decorative elements are purchased separately. Such elements include: flowers, peaks, monograms and others. All you need to do is weld them to the finished product, then clean the weld seams with a grinder and paint the product in the desired color. The main color in which products are painted is matte black, but the ability to work with paint will help you create truly unique products. By mixing paints, you can achieve the color of aged bronze or copper, which will give your product some special character.

Cold forging, unlike hot forging, gives many advantages and allows you to produce unique products, such as fences, gratings, fences, canopies, flower beds, door hinges, accessories for fireplaces, , smokehouses, chandeliers, candlesticks, figurines of people and animals as decorative elements and much more.

Find a good supplier of decorative elements, usually a good supplier will have over 1000 different elements.
The final price for metal cold forging products consists of the cost of raw materials, the complexity of the work, the resources spent (fuels and lubricants, electricity), plus 100% of your work. That is, the profitability of a cold forging business is at least 100%.

How can you realize your abilities?
At the initial stage, it is better to take a training course, at least self-training in forging. If your city has forging courses, or, in extreme cases, welding courses, take them. If there are no such courses, then study on your own. Surely in your city there are already companies that produce forged products; offer them your services as an independent craftsman, in case of a large number of orders. It will be good if you are offered a job, you can study and at the same time receive money; forging masters earn an average of 40,000 rubles. per month, with such an income, you can save up for a good set of equipment. When working in a company, keep in mind the main goal - to create your own company for the production of forged products.

Sales of cold forging products.
As a rule, all products are made to order according to individual wishes and sizes, so making products for sale is not the best option. It will be better if you start looking for clients. Which you can see in the faces of the owners of country houses. These are the main clients.

Legal entities can also become good clients, this is the design of cafes, restaurants, bars, the exterior design of buildings, from gratings to porches.

To summarize, we can say that the business of cold forging of metal products is not devoid of a creative process, not in the actual production of objects, but also in the options for selling finished products. Based on this, the conclusion suggests itself - the more creative abilities you have, the more you can achieve in this business. Happy forging!

Forged products have long been very popular all over the world, and artistic forging occupies a special place. Her beauty fascinates with its graceful and smooth lines, original beauty. Many rich people sought to decorate their home with openwork metal curls of various products that decorated the interior and exterior design of mansions.

Many of us understand what forging is, so we immediately imagine a forge in which a blacksmith operates a hammer, turning a piece of hot metal into a beautiful forged product. So, what happens when it comes to hot forging, in cold forging everything is different, it does not require a hot workpiece, metal can be processed manually at home. How this happens, what kind of process this is, what types of forged products are made in this way can be seen in the photo of product samples and by reading the article.

Cold forging products

Features of cold forging

Method of artistic metal processing is the most popular- This is a fast and high-tech process. The beauty of the finished products can be assessed in catalogs where photos of the best works are presented. Using this method, you can create products that are much stronger than those made using stamping or casting. This is explained by the fact that the metal, passing through the equipment, can be bent and pressed at the same time.

During forging, pressure is applied to the metal and it strengthens it, resulting in a part that is subsequently almost indestructible. Cold forging method Can be done by experienced professionals, since if processing is done incorrectly, it will be very difficult to repeat the actions with the workpiece again. The properties of cold forging make it possible to create various products used in houses and apartments, in courtyards and streets, since forged products are very popular:

• fences and railings;
• window grilles;
• fences and stairs;
• gazebos, lanterns and barbecues;
• elements for decorating fireplaces;
• furniture and interior items.

And this is still an incomplete list of items that can be made using the cold forging method. Items obtained in this way, as can be seen in the photo, can decorate any interior with their own shapes and style.

Necessary equipment for creating products at home

Over time, new technologies allowed the first invention and then creation of a set of specialized tools to expand the capabilities of blacksmiths. Even inexperienced craftsmen can work with such tools; working with them is not very difficult.

One of the main items in the work is a bender; it is always available in any workshop that works with metal. With its help, you can bend the workpiece at the desired angle or an arc of the required radius.

The snail creates spirals from selected blanks; spirals are often found in blacksmiths' workshops. snail you can buy it or make it yourself, and also make a spiral with any radius that the master thinks of.

A flashlight is the most complex tool; having such a device, you can not work with a separate part, but immediately create a whole complex from single rods. Tool helps create types of baskets from metal rods of various diameters and sections. Despite the fact that many new and modern types of materials have appeared that are suitable for decorating country houses, most people prefer forged products. Although metal can corrode unlike new materials, forging remains in demand for many reasons:

• durability and beauty;
• good protective functions;
• the ability to order a product according to individual sizes, sketches and in any style;
• handmade, products are always combined with other materials.

The list of advantages of artistic forging can be continued, since such products perfectly combine many positive qualities. The photos presented on the websites vividly characterize the beauty, functionality and durability of the products.

The only disadvantages include the high cost of forging and the sensitivity of the metal to corrosion. If the products are too complex in design, they will be difficult to process and paint.

Painting for forged metal

Experts recommend using a primer before painting so that in the future even the best and most expensive paint will not lose its properties so quickly. High-quality primers have good adhesion, and this allows paints to better penetrate the surface of the object.

Good paints contain rust converters; it is better to apply them in two layers. The best choice is industrial types of paints, they are expensive, but provide reliable and durable coverage. They dry quickly, and you can easily apply another color you like if you wish.

Cost of products

Many websites present catalogs with photos and prices of forged products. Grilles, canopies, awnings, home and landscape interior items look very impressive and beautiful. There are craftsmen who work on unusual objects, for example, sculptures of knights, also made of forged metal.

To better view the photo, you can enlarge the picture, and also read the description of the presented product with its dimensions, find out the price per linear meter or for the entire item.

Many companies offer to complete an individual order to obtain an exclusive product using cold forging. To do this you will need a sketch or drawing, photo and the finished forged product in the hands of craftsmen will turn out almost identical those sketches that the customer brings.

Do-it-yourself cold forging can be an interesting and useful activity for many. This will require financial costs for the purchase of the necessary tools, materials, equipment, as well as premises, if there is no suitable one. In addition to financial costs, it is important to have free time and desire to create your own compositions using the cold forging method, and the necessary experience will come with time.

Cold forging is impossible without a special forge equipment. Let's look at the types of devices and the figures that can be obtained with their help. We have prepared drawings and thematic videos for you. We will also consider the sequence of making a cold forging machine with your own hands.

If you are just going to organize a cold forging workshop and want to avoid large expenses, then making your own machines and fixtures will help you create your own small business without excessive costs.

Basic devices and machines

Cold forging machines are mainly designed for arc or angle bending, as well as twisting. They can be manual or electrically driven.

The main types of machines and devices for cold forging:

• Gnutik
• Twister
• Snail
• globe
• Wave
• Flashlight

Device "Gnutik"

Purchased or made independently, the “Gnutik” is a universal device that allows you to obtain an arc or angle from a rod. It consists of a base with a slider, on which a stop with an angle (90° or another as necessary) and two cylindrical fixed stops are fixed. By moving the slider and the angle stop, the rod bends at an angle. To obtain an arc, a third cylinder is provided, rotating on the side opposite to the angle stop.

The device can be made on a horizontal or vertical platform.

Axonometry of the "Gnutik" device - vertical arrangement

To scale the dimensions, here is a drawing of the bottom bar of this “Gnutik”.

Bottom bar

This device is universal. With the help of attachments you can not only bend, but also cut and punch holes. But this will be the next step.

Getting an arc on "Gnutik"

Getting an angle on "Gnutik"

This is what a homemade “Gnutik” looks like:

Twister device

"Twister" - tool for twisting rods, mostly square, along the longitudinal axis. This simple device can be manual or electric. Operating principle: both ends of the rod are secured, then one fastening begins to rotate, twisting the metal to the required shape.

Appearance of a purchased manual “Twister”

Look at the photo of a homemade “Twister” with an electric drive, assembled using used electrical equipment:

There is a special machine for making “Lanterns” and “Cones”, but for starters you can also use a “Twister”, as shown in the video (English, but everything is very clear).

Video: how to make a blank for “Flashlight” on “Twister”

Device "Snail"

The Snail Tool is designed to create curls (or spirals) and “currencies” (S-shaped pieces). Various designs are available.

One of the design options: 1 - snail ploughshare; 2 - base of the machine; 3 — pressure roller; 4 — lever for controlling the pressure roller; 5 — fastening the base; 6 — finger for fixing the plowshares; 7 — groove for the pressure roller; 8 — control lever axis; 9 — spring for pressing the roller; 10 — clamp for the workpiece; 11 — leading ploughshare of the snail; 12 — main axis; 13 — levers

The result should be something like this:

Another lightweight design for bending rolled products with a cross-section up to 12 mm:

1 - cochlear segment; 2 - eccentric; 3 - handle; 4 - base; 5 — guide runners; 6 - axis; 7 - slider; 8 — axle nut; 9 — roller mounting axis; 10 - roller; 11 — drive axis; 12 — eccentric guide; 13 - central segment of the cochlea; 14 — eccentric wing; 15 — main leg; 16 — connecting pin of cochlea segments; 17 — adjustment screw; 18 - connecting ear of cochlear segments

Often the “Snail” device is made on a support, especially if you need to bend thick rolled products.

Several useful videos on homemade “Snail” machines.

Making a snail

Machine operation

We will talk more about such designs below.

Globus device

Such a device is similar in appearance to a school protractor and is designed for making arcs with a large bending radius from a strip, square, circle or hexagon. First, one end of the workpiece is fixed with a bend, then it is bent along its entire length according to the template. The principle of operation is somewhat similar to the operation of a canning machine.

Appearance of the device

Video of work at Globus

Using purely muscular force, a large diameter arc can be made on a template screwed or welded to a workbench. It is good for bending strips, thin-walled pipes, etc.

Sample

Device "Wave"

You can produce wavy products from a round, square, hexagonal cross-section or tube using the “Wave” device. The deformation of the workpiece occurs between vertical rolls by scrolling.

Wave device and resulting products

Device in action

Flashlight device

This machine produces blanks for “Lanterns” or “Pine Cones” elements, which can consist of 4, 6, 8 or more rods. According to the principle of operation, the machine is similar to the “Twister”, but here the workpieces are bent around the guide shaft, which forms a more correct and accurate configuration of the product.

Flashlight device

Operation of the device for making “Flashlight”

Device for cold forging of the “Clamp” element

The cold forging element “Clamp” is designed to fix other structural elements together.

The device for bending the “Clamp” can be made according to the attached drawings.

Devices for making crow's feet

“Crow's foot” - flattening with the application of beautiful notches at the ends of the workpieces to make the structure more elegant or to reduce the thickness for various joints.

The ends of the elements are decorated with “houndstooth”

This operation can be performed using a machine with a die or fixture and a heavy forging hammer on an anvil. We provide both options in the form of videos.

Machine for making houndstooth

Tools for forging crow's feet

Detailed stamp making process

Below is a rolling machine to perform the same operation.

Machine for rolling "crow's feet" (the distance between the rollers is adjustable).Materials for a rolling machine: gears and shafts - spare parts from a used combine

Operating principle

Making a "Snail" with a drive

The electrically driven "snail" facilitates the production of curls and "currencies". This is especially valuable when the work is not “for the soul”, but for the production of a large number of similar products on stream when working to order.

Below are the stages of assembling a machine for bending a rod with a maximum cross-section of 10x10 mm. The 0.5 kW/1000 rpm engine operates at the limit of its capabilities. Performs 6 shaft revolutions per minute. The snail segments are machined from a round blank St.45 without heat treatment, 25 mm high and 20 mm thick. The volute is mounted on a shaft on bearings from the rear wheel of a motorcycle - 7204. The support roller is firmly fixed in the groove. Pulleys are installed between the engine and the gearbox.

Below are drawings of the cochlea segments.

Snail element 1

Snail element 2

Snail element 3

Snail centerpiece

For a more massive rod (from 12 mm), the motor power should be more than a kilowatt. The photographs below show a machine with a 2.2 kW, 1000 rpm motor, giving a shaft output of about 10 rpm. This is already a machine for professional use. A used gearbox was used, the matrix was cut from a 30 mm thick workpiece - the most labor-intensive process.

For cold forging you will also need an anvil and a hammer. A forge is not needed, it is only required for hot forging.

Advice! Before starting work, draw a full-size sketch of the future structure. This will help you adjust the elements and not get confused during assembly.