Departments› Mechanical Production Technician› Module V› Forging Works› Ch 4: Set up forging tools and equipment
Mechanical Production Technician  ·  Level 6
Forging Works
Chapter 4: Set up forging tools and equipment
📚 1 Topics
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⚑ What you will be able to do

By the end of this chapter, you will be able to:
- safely and correctly check the condition of forging equipment by following the manufacturer’s manual
- correctly mount the tools and accessories needed for your forging tasks
- accurately set the forging equipment parameters according to the manufacturer’s instructions

Mastering these skills ensures your forging work is safe, efficient, and produces high-quality results every time.

Forging is a fundamental process in mechanical production that involves shaping metal using compressive forces. Setting up forging tools and equipment correctly is critical to achieving the desired mechanical properties and dimensional accuracy of forged components. In Kenya, mechanical production technicians working in manufacturing firms, metal workshops, and automotive parts industries must understand the parameters that influence forging operations to optimize productivity and ensure quality. This chapter focuses on key forging equipment parameters, explaining their roles and practical considerations in forging setups.

4.2 Forging Equipment Parameters

The parameters governing forging equipment directly affect the efficiency, safety, and quality of the forging process. Mechanical production technicians in Kenya must master these parameters to select appropriate machines and tooling for various forging tasks, such as producing agricultural implements, vehicle components, or construction hardware. Understanding the interplay of force, power, material dimensions, and thermal conditions is essential for minimizing defects and extending tool life.

4.2.1 Force

Force in forging determines the capacity of the equipment to reshape metal blanks by applying compressive stress. It is influenced by the size, shape, and mechanical properties of the workpiece, as well as the type of forging operation. Kenyan manufacturers producing heavy-duty parts for machinery or automotive sectors must calculate and control forging force accurately to prevent tool damage and ensure dimensional precision.

Definition of Forging Force

Forging force is the magnitude of compressive load applied by the forging equipment to deform the metal workpiece plastically. It is measured in kilonewtons (kN) or tonnes and varies with the material’s yield strength and the deformation characteristics.

Factors Affecting Forging Force

  • Material strength: Metals with higher yield strength require greater force to deform, such as alloy steels used in industrial machinery components.
  • Workpiece geometry: Larger or thicker blanks increase the forging force needed due to increased volume resisting deformation.
  • Forging temperature: Higher temperatures reduce material strength and thus lower required force, as seen in hot forging of steel parts.
  • Die design: Complex dies with tighter tolerances may require increased force to achieve accurate shapes.
  • Friction between tool and workpiece: Higher friction increases force demand as energy is lost overcoming surface resistance.

Measuring and Controlling Forging Force

Modern forging presses are equipped with load cells or sensors to monitor applied force in real-time, enabling technicians to adjust parameters for consistent results. For instance, a SACCO metal workshop producing forged handles may calibrate force to avoid excessive tool wear.

Impact of Excessive or Insufficient Force

Applying excessive force can cause premature die failure, excessive flash, or damage to the forging press. Insufficient force results in incomplete filling of the die cavity, producing defective parts. Accurate force estimation prevents these issues and improves production efficiency.

4.2.2 Blank Size

The blank is the initial metal piece that is forged into the desired shape. Proper blank sizing is essential to ensure material efficiency and dimensional accuracy in the finished product. Kenyan fabrication workshops making agricultural tools or hardware must select blanks that match forging design specifications.

Importance of Correct Blank Size

A correctly sized blank minimizes waste and ensures the forging die is fully filled during deformation, avoiding defects such as laps or underfills.

Methods of Determining Blank Size

Technicians calculate blank size based on the volume of the finished part, accounting for material flow, flash allowance, and shrinkage during cooling.

Influence on Forging Force and Equipment Selection

Larger blanks require equipment with higher force capacity and power. For example, a metal workshop producing large spanners must use forging presses rated for the required blank size.

Impact of Incorrect Blank Size

Undersized blanks lead to incomplete die filling, while oversized blanks cause excessive flash and increased finishing work, reducing cost-effectiveness.

4.2.3 Power

Power refers to the rate at which the forging equipment can do work to deform the metal. It combines the force applied and the speed of deformation. Power capacity influences production rates and suitability for different forging operations.

Definition of Power in Forging

Power is the product of forging force and the velocity of the ram or hammer, expressed in kilowatts (kW).

Relationship Between Power and Production Efficiency

Higher power allows faster deformation cycles, increasing throughput in high-demand environments such as automotive parts manufacturing.

Power Requirements for Different Forging Processes

Processes like drop forging require high power for rapid hammer blows, while press forging demands steady power for slow, controlled deformation.

Power Source Considerations in Kenya

Kenyan workshops may use electric, hydraulic, or mechanical power sources. Availability and cost of electricity influence equipment choice, especially in rural areas where power supply can be unstable.

4.2.4 Forging Projection Area

The forging projection area is the surface area of the workpiece exposed to the forging force, affecting stress distribution and equipment loading. Accurate calculation helps optimize die design and forging parameters.

Definition and Significance

Projection area refers to the cross-sectional area perpendicular to the direction of force during forging. It determines how force is distributed over the workpiece.

Calculation Methods

Technicians calculate projection area based on the die cavity shape and workpiece geometry, often using engineering drawings or CAD models.

Influence on Forging Force and Die Design

Larger projection areas require higher forces but reduce localised stress concentrations, extending die life.

4.2.5 Fillet Volume

Fillets are rounded transitions between surfaces in forged parts that reduce stress concentrations and improve durability. The volume of fillets influences material flow and force requirements.

Role of Fillets in Forging

Fillets help in smooth material flow during forging, preventing cracks and improving mechanical performance of the finished part.

Impact on Material Usage

Larger fillet volumes increase the amount of metal required, affecting blank size and cost efficiency.

Influence on Forging Force and Die Wear

Fillets require careful control as they affect force distribution and can accelerate die wear if improperly designed.

Design Considerations in Kenyan Production

In agricultural implement production, fillet design balances strength and material economy to produce durable tools at competitive costs.

4.2.6 Ideal Work of Deformation

The ideal work of deformation represents the theoretical energy needed to plastically deform the metal in forging without losses. It sets a benchmark for process efficiency.

Definition and Theoretical Basis

It is the minimum work required to change the shape of the metal, calculated from material flow stress and strain.

Factors Affecting Work of Deformation

Material properties, temperature, strain rate, and die design influence actual work compared to ideal.

Measuring and Approximating Work

Technicians use empirical formulas or simulations to estimate work, aiding in equipment sizing and energy planning.

Application in Kenyan Industry

In foundries producing engine components, minimizing excess deformation work reduces energy consumption and production costs.

4.2.7 Friction Force

Friction force arises between the workpiece and forging tools, impacting the energy needed and the quality of forged parts. Managing friction is vital in Kenyan workshops to optimize tool life and surface finish.

Sources of Friction in Forging

Contact between dies and hot metal surfaces generates friction, influenced by lubrication and surface roughness.

Effects on Forging Force and Tool Wear

Higher friction increases force requirements and accelerates die wear, increasing maintenance costs.

Methods for Friction Reduction

Use of lubricants such as graphite or oil, surface texturing, and die coatings reduce friction in forging operations.

Practical Considerations in Kenya

Cost and availability of lubricants influence friction management strategies in Kenyan metal workshops.

4.2.8 Interface Shear

Interface shear refers to the shear stresses at the contact surface between the workpiece and forging tools, affecting metal flow and die life.

Definition and Importance

Shear at the interface governs how metal slides or sticks to the die, influencing material flow patterns.

Impact on Forging Quality

Excessive shear can cause surface defects or uneven deformation, compromising part integrity.

Factors Influencing Interface Shear

Temperature, lubrication, and surface finish of dies significantly affect interface shear.

Monitoring and Control

Technicians monitor shear effects through process parameters and adjust lubrication or temperature to optimize results.

4.2.9 Temperature

Temperature critically affects material properties, deformation behavior, and tool life in forging. Maintaining the correct temperature range is a key responsibility for mechanical production technicians.

Role of Temperature in Forging

Elevated temperatures reduce yield strength and increase ductility, facilitating deformation.

Temperature Control Methods

Preheating blanks and dies, furnace management, and rapid transfer to forging equipment ensure optimal temperatures.

Effects of Temperature Variations

Too low temperatures cause cracks and high force requirements; too high temperatures promote oxidation and scaling.

Kenyan Industry Practices

In metal workshops producing forged tools, temperature monitoring using pyrometers and thermocouples ensures consistent product quality.

Practice Questions

  1. Explain the factors that influence forging force and how they affect the forging process. (10 marks)
  2. Discuss the importance of blank size in forging and the consequences of incorrect blank sizing. (10 marks)
  3. Describe how power affects forging operations and the considerations for power source selection in Kenyan workshops. (10 marks)
  4. Define forging projection area and explain its impact on forging force and die design. (10 marks)
  5. Discuss the role of fillet volume in forging and how it influences material usage and die wear. (10 marks)
  6. Explain the concept of ideal work of deformation and its significance in forging process efficiency. (10 marks)
  7. Identify sources of friction force in forging and methods to manage it in Kenyan production settings. (10 marks)
  8. Describe interface shear and its impact on forging quality and tool life. (10 marks)
  9. Explain the importance of temperature control in forging and methods used to maintain optimal temperatures. (10 marks)

Chapter Summary

This chapter focused on the essential tools and equipment used in forging works, starting with presses, including hydraulic presses that provide controlled force through fluid pressure, and mechanical presses that operate using mechanical advantage for rapid and precise forging. It then examined heating furnaces, which are critical for elevating metal temperatures to achieve the necessary plasticity for shaping. The discussion included hammers, key for delivering impactful blows during forging, and dies, which shape the workpiece while withstanding high stresses. Rolling mills were described as equipment used to reduce thickness and shape metal by passing it between rolls, and trimming machines were covered for their role in removing excess material from forged parts. The chapter also detailed important forging equipment parameters such as the force applied, blank size, power requirements, forging projection area, fillet volume, and the ideal work of deformation needed for efficient shaping. Additionally, it addressed the effects of friction force, interface shear, and temperature on the forging process, emphasizing their influence on material flow and final product quality.

Self-Assessment

🔒 PDFDownload this self-assessment, with answers

A. Written Assessment

  1. What is the main difference between a hydraulic press and a mechanical press in forging operations? (3 marks)
  2. List four key safety considerations when setting up a heating furnace for forging. (4 marks)
  3. Explain how the blank size affects the choice of forging equipment parameters. (3 marks)
  4. Which forging equipment is primarily used to remove excess material after forging? (1 mark)
  5. Describe the role of dies in forging and why their maintenance is critical. (4 marks)
  6. What parameter in forging determines the amount of force required to shape the metal? (2 marks)
  7. How does temperature influence the forging process and the quality of the forged product? (3 marks)
  8. Define ‘ideal work of deformation’ in the context of forging and its significance. (3 marks)
  9. Identify two effects of friction force during forging and how it can be managed. (4 marks)
  10. What is the function of rolling mills in forging works? (2 marks)
Show Answers
  1. A hydraulic press uses fluid pressure to generate force, allowing for slower, controllable movements and higher force at low speeds. A mechanical press uses mechanical linkages and flywheels, producing faster, repetitive strokes but typically less force control.
  2. Safety considerations include: ensuring proper ventilation to avoid toxic fumes, checking for gas leaks, using protective gear to prevent burns, and maintaining clear emergency shut-off access.
  3. Blank size determines the volume and shape of the workpiece; larger blanks require equipment with higher force capacity and larger die sizes to accommodate the material without defects.
  4. The trimming machine is used to remove excess material after forging.
  5. Dies shape the metal by providing the mold for deformation; maintenance is critical to prevent defects, ensure dimensional accuracy, and extend die life under high stress and temperature.
  6. The force parameter determines the amount of pressure needed to deform the metal during forging.
  7. Temperature affects metal plasticity; higher temperatures reduce flow stress, making deformation easier and improving grain structure, but excessive heat can cause oxidation or grain growth, reducing quality.
  8. Ideal work of deformation refers to the theoretical minimum energy required to deform the metal without losses; it helps in designing efficient forging processes and selecting equipment.
  9. Friction force resists metal flow and generates heat; it can cause wear on dies and affect dimensional accuracy. It can be managed by lubrication and die surface treatments.
  10. Rolling mills reduce the thickness and alter the cross-sectional profile of metal, preparing it for subsequent forging or finishing operations.

B. Oral Assessment

  1. Discuss how the selection of forging equipment parameters such as force, temperature, and blank size impacts the quality and efficiency of forging operations at a manufacturing firm like ARM Cement.
  2. Explain the advantages and limitations of hydraulic presses versus mechanical presses in a forging workshop setting, considering factors such as production volume, precision, and maintenance.
Answer Guide

Question 1 key points:

  • Proper force selection ensures the metal is shaped without defects or excessive tool wear.
  • Temperature control influences metal workability and microstructure, affecting final product strength.
  • Blank size must match equipment capacity to avoid under or over-forging, which impacts efficiency and cost.
  • Balancing these parameters improves throughput and reduces scrap rates.

Question 2 key points:

  • Hydraulic presses allow precise force control and are suited for complex shapes and variable loads but have slower cycle times.
  • Mechanical presses offer faster production rates and are cost-effective for high-volume forging but have less force flexibility and higher maintenance.
  • Choice depends on production demands, product complexity, and workshop resources.

C. Case Study

At Kenyatta National Hospital’s biomedical engineering workshop, forging tools and equipment are being set up to produce custom surgical instrument components.

Tasks:
a) Identify appropriate forging equipment and justify your selection based on the blank size and required forging force. (5 marks)
b) Outline the critical parameters to monitor during the heating process to ensure material integrity. (5 marks)
c) Propose maintenance and safety measures for the dies and presses in this healthcare equipment forging context. (5 marks)

Suggested Approach

a) Selection should consider mechanical or hydraulic presses capable of applying precise force suitable for small to medium-sized surgical instrument blanks; hydraulic presses offer better control for delicate shapes.
b) Monitor furnace temperature closely to maintain optimal metal plasticity without overheating, ensure even heating to avoid thermal gradients, and control heating duration to prevent grain growth or oxidation.
c) Implement regular inspection schedules for wear and cracks on dies, apply lubrication to reduce friction, train operators on safe press operation, and establish emergency stop procedures to prevent accidents.

Chapter Examination Questions

🔒 PDFDownload these examination questions, with worked answers

SECTION A (40 Marks) - Answer ALL Questions

  1. Explain the main operational difference between a hydraulic press and a mechanical press used in forging, and give an example of where each might be applied in a Kenyan workshop. (4 marks)
  2. Describe the role of a heating furnace in the forging process and discuss why temperature control is critical for successful forging. (4 marks)
  3. Identify three types of hammers used in forging and explain how their characteristics affect the forging outcome. (4 marks)
  4. What are forging dies, and how does their design influence the quality of forged components? (4 marks)
  5. Outline the function of a trimming machine in forging and explain its importance in production at a metal fabrication plant. (4 marks)
  6. Define forging projection area and discuss how it affects the selection of forging equipment. (4 marks)
  7. Examine the impact of friction force during forging and how it can be managed in a typical Kenyan forging workshop. (4 marks)
  8. Discuss the relationship between blank size and forging force requirements, with reference to a practical forging scenario. (4 marks)
  9. Explain the term ‘ideal work of deformation’ and its significance in assessing forging efficiency. (4 marks)
  10. Describe how interface shear affects the forging process and suggest methods to minimize its negative effects. (4 marks)
Section A - Answers
  1. A hydraulic press uses fluid pressure to generate force, allowing variable speed and pressure control, suitable for heavy, slow forging such as in large component shaping at a county fabrication workshop. Mechanical presses use mechanical energy from a motor and flywheel, producing rapid, repetitive strokes ideal for mass production like bolt forging at a Nairobi industrial metalworks.
  2. The heating furnace raises the metal’s temperature to make it malleable, reducing resistance to deformation. Precise temperature control prevents overheating or underheating, which could cause defects or cracking, essential in forging components such as agricultural tools at a cooperative workshop.
  3. Common hammers include power hammers, pneumatic hammers, and trip hammers. Power hammers deliver rapid, high-energy blows for shaping; pneumatic hammers offer controlled impact useful for delicate forging; trip hammers provide heavy, slow blows suitable for large forgings, affecting surface finish and accuracy.
  4. Forging dies shape the metal and define the final component geometry. Their design affects dimensional accuracy, surface finish, and material flow. Poorly designed dies can cause defects such as laps or cracks, impacting quality in products like vehicle parts manufactured in Kisumu.
  5. A trimming machine removes excess flash and unwanted material after forging, ensuring components meet dimensional standards. This step is vital in maintaining production efficiency and quality, for example in a metal parts factory supplying Nairobi’s automotive industry.
  6. Forging projection area is the surface area of the metal that comes into contact with the dies during forging. Larger projection areas require greater force and influence the choice of press capacity to ensure proper deformation without equipment damage.
  7. Friction force resists metal flow between the die and workpiece, increasing required forging force and causing uneven deformation. Applying lubricants and maintaining die surface finish are common practices to reduce friction in workshops such as those in Eldoret.
  8. Larger blank sizes require higher forging forces due to increased volume and resistance, affecting equipment selection and energy consumption. For example, forging a large agricultural ploughshare blank demands a more powerful press than smaller tool blanks.
  9. Ideal work of deformation refers to the theoretical minimum energy needed to deform the metal without losses. It is used as a benchmark to evaluate the efficiency of the forging process and to optimize parameters like force and temperature.
  10. Interface shear occurs at the contact surface between the die and workpiece, potentially causing surface damage or die wear. Using appropriate lubricants and selecting compatible die materials help to reduce interface shear effects in forging shops.

SECTION B (60 Marks) - Answer any TWO Questions

Question 11 (Compulsory - 20 marks)
At a medium-sized forging workshop in Nakuru supplying components to the local automotive industry:
a) Describe how you would set up a hydraulic press for forging a steel gear blank, including considerations of force, power, and temperature. (10 marks)
b) Explain the parameters you would monitor during the forging operation to ensure product quality and equipment safety. (10 marks)

Question 12 (20 marks)
Discuss the advantages and limitations of mechanical presses compared to hydraulic presses in forging operations, citing examples from Kenyan manufacturing industries.

Question 13 (20 marks)
Analyze how the choice of forging dies and trimming machines affects production efficiency and component quality in a county government metal fabrication workshop.

Question 14 (20 marks)
Explain the relationship between forging equipment parameters such as blank size, forging projection area, and friction force, and how their management influences the success of forging operations in a SACCO-owned metalworks.

Section B - Answers

Question 11
a) Setting up a hydraulic press involves selecting a press with adequate force rating to deform the steel gear blank, ensuring the power source can sustain the required pressure, and preheating the blank in a furnace to the optimal forging temperature (typically 1100–1250°C for steel). The press stroke length and speed must be adjusted to match the gear design, minimizing metal defects. Safety checks on hydraulic lines and control systems are critical.
b) Parameters to monitor include forging force to avoid overstressing the press, blank temperature to maintain material ductility, power consumption to detect anomalies, and die condition to prevent damage. Continuous lubrication and monitoring of hydraulic fluid levels ensure smooth operation and prevent breakdowns.

Question 12
Mechanical presses offer high-speed operation and are suitable for high-volume production with consistent product dimensions, as seen in Nairobi’s bolt manufacturing plants. However, they have limited force control and slower adjustment times. Hydraulic presses provide flexible force control and can handle larger parts with varying shapes, used in county workshops forging large agricultural implements. Their slower speed and higher maintenance costs are limitations.

Question 13
Forging dies designed with precise geometry reduce metal waste and improve dimensional accuracy, enhancing quality. Efficient trimming machines remove flash quickly, reducing cycle time and labor costs. In county workshops, investing in durable dies and automated trimming improves throughput and product consistency, meeting client specifications more reliably.

Question 14
Blank size determines the volume of metal to be deformed, influencing required forging force and energy consumption. Forging projection area affects contact pressure, requiring adjustments in press capacity. High friction force increases resistance, raising deformation force and die wear. Managing these parameters through proper blank preparation, die lubrication, and equipment selection ensures successful forging outcomes in SACCO metalworks.

References

  1. TVET CDACC - Forging Works Curriculum (Cycle 3, 2025)
  2. TVET CDACC - Forging Works Occupational Standards

Chapter Practical Activities

Practical 1: Set up and calibrate hydraulic press for forging

Mechanical Production Technician · Level 6
Forging Works
PRACTICAL ASSESSMENT
TIME: 4 HOURS
⬇ PDFCandidate Instructions (Candidate Tool)

Type: Individual

INSTRUCTIONS TO CANDIDATE:
1.  You are required to perform the following task:
i.  Set up and calibrate the hydraulic press for forging mild steel billets 100 mm x 50 mm x 12 mm, ensuring correct force and power settings.
2.  You have been provided with the following resources for the practical task:
Tools & EquipmentMaterials
Hydraulic press machineMild steel billets 100 mm x 50 mm x 12 mm
Hydraulic pressure gauges
Vernier caliper
Steel rule
Scriber
Set of spanners
Pressure relief valve wrench
Clear safety goggles
Leather gloves
Apron/dust coat
Safety boots
Cotton waste
Cleaning brush
⬇ PDFResources Required (Cutting List)
S/NItemQuantity
1Hydraulic press machine1 Pc per Candidate
2Mild steel billets 100 mm x 50 mm x 12 mm2 Pcs per Candidate
3Set of hydraulic pressure gauges1 Set per Candidate
4Force calculator chart (table or manual)1 Pc per Candidate
5Vernier caliper1 Pc per Candidate
6Steel rule1 Pc per Candidate
7Scriber1 Pc per Candidate
8Set of spanners1 Set per Candidate
9Pressure relief valve wrench1 Pc per Candidate
10Clear safety goggles1 Pair per Candidate
11Leather gloves1 Pair per Candidate
12Apron/dust coat1 Pc per Candidate
13Safety boots1 Pair per Candidate
14Cotton wasteEnough per Candidate
15Cleaning brush1 Pc per Candidate
⬇ PDFAssessor Guide
Items to be EvaluatedMarks AvailableMarks ObtainedComments
TASK 1: Safety and Preparation
Wore PPE: safety boots, clear goggles, leather gloves, apron/dust coat
(Award 1 mark for each PPE item worn correctly)		4
Observed machine safety: ensured machine is off before setup, no speed changes while running, machine guard in place
(Award 2 marks for all machine safety observations)		2
Prepared operation plan including force and power requirements based on billet size
(Award 4 marks for a complete and correct operation plan)		4
Sub-Total10
TASK 2: Hydraulic Press Setup and Calibration
Mounted and secured mild steel billets correctly on the press bed
(Award 2 marks for correct mounting and securing)		2
Set hydraulic pressure using pressure gauges to achieve required forging force
(Award 4 marks for correct pressure setting consistent with force calculator)		4
Adjusted power settings and verified hydraulic pump operation
(Award 3 marks for proper power setting and pump operation)		3
Tested press operation with no load and under load safely
(Award 3 marks for safe and successful test runs)		3
Sub-Total12
TASK 3: Housekeeping and Final Checks
Cleaned the hydraulic press and surrounding work area using cotton waste and cleaning brush
(Award 2 marks for thorough cleaning)		2
Returned tools and accessories to designated storage areas
(Award 1 mark for proper tool storage)		1
Disposed waste in the correct bin
(Award 1 mark for correct waste disposal)		1
Sub-Total4
PRODUCT CHECKLIST
Hydraulic press set up with correct force to deform mild steel billet 100 mm x 50 mm x 12 mm
(Award 6 marks if force setting matches calculated requirement within tolerance)		6
Power settings adjusted to operate press efficiently without overload
(Award 4 marks if power setting is correct and press runs smoothly)		4
No safety faults or machine damage observed during operation
(Award 4 marks for safe and correct operation)		4
Sub-Total14
GRAND TOTAL40
ASSESSMENT OUTCOME:   ☐ Competent    ☐ Not Yet Competent (competent if at least 50%)

Practical 2: Set up mechanical press for forging 500 kN capacity with 1000 mm throat depth

Mechanical Production Technician · Level 6
Forging Works
PRACTICAL ASSESSMENT
TIME: 4 HOURS
⬇ PDFCandidate Instructions (Candidate Tool)

Type: Individual

INSTRUCTIONS TO CANDIDATE:
1.  You are required to perform the following task:
i.  Set up and adjust a mechanical press 500 kN capacity with 1000 mm throat depth for forging as per the operation manual and safety standards.
2.  You have been provided with the following resources for the practical task:
Tools & EquipmentMaterials
Set of spanners (metric sizes 10mm to 24mm)Mechanical press 500 kN capacity with 1000 mm throat depth
Vernier caliper 0-150 mmClear safety goggles
Feeler gauge set (0.02 mm to 1.0 mm)Leather gloves
Steel rule 300 mmSafety boots
Cotton waste for cleaning
⬇ PDFResources Required (Cutting List)
S/NItemQuantity
1Mechanical press 500 kN capacity with 1000 mm throat depth1 Pc per Candidate
2Set of spanners (metric sizes 10mm to 24mm)1 Set per Candidate
3Vernier caliper 0-150 mm1 Pc per Candidate
4Feeler gauge set (0.02 mm to 1.0 mm)1 Set per Candidate
5Steel rule 300 mm1 Pc per Candidate
6Mechanical press operation manual1 Pc per Candidate
7Clear safety goggles1 Pair per Candidate
8Leather gloves1 Pair per Candidate
9Safety boots1 Pair per Candidate
10Cotton waste for cleaningEnough per Candidate
11Broom and cleaning materialsEnough per Candidate
⬇ PDFAssessor Guide
Items to be EvaluatedMarks AvailableMarks ObtainedComments
TASK 1: Safety and Preparation
Wore all prescribed PPEs: safety boots, clear goggles, leather gloves
(Award 1 mark for each correctly worn PPE)		3
Checked mechanical press for physical safety: no loose parts, machine guards in place
(Award 2 marks for complete and correct safety check or zero)		2
Ensured machine is switched off before setting up
(Award 1 mark for observation or zero)		1
Prepared operation plan as per mechanical press manual
(Award 1 mark for each correctly described step)		4
Sub-Total10
TASK 2: Mechanical Press Setup and Adjustment
Selected appropriate die and tooling for forging operation
(Award 2 marks for correct tooling selected or zero)		2
Mounted die securely on press bed using correct spanners
(Award 3 marks for secure mounting and correct tools used)		3
Set ram stroke and adjusted press stroke length as per forging requirement
(Award 3 marks for correct stroke adjustment or zero)		3
Adjusted force settings to 500 kN according to press specifications
(Award 4 marks for correct force setting or zero)		4
Checked power settings and ensured motor parameters are within safe limits
(Award 3 marks for correct power setting or zero)		3
Tested press operation without load to verify settings
(Award 3 marks for successful test run or zero)		3
Sub-Total18
TASK 3: Housekeeping after Setup
Cleaned mechanical press using cotton waste
(Award 1 mark for cleaning or zero)		1
Cleared work area and disposed waste in correct bin
(Award 1 mark for cleaning or zero)		1
Returned tools and accessories to their designated places
(Award 1 mark for proper tool return or zero)		1
Sub-Total3
PRODUCT CHECKLIST
Mechanical press set up with ram stroke adjusted to 1000 mm ±5 mm
(Award 4 marks for correct stroke length or zero)		4
Force setting calibrated accurately to 500 kN ±10 kN
(Award 5 marks for correct force setting or zero)		5
Power settings stable within manufacturer's recommended range
(Award 3 marks for stable power settings or zero)		3
Press operation test run successful without abnormal noise or vibration
(Award 3 marks for successful test run or zero)		3
Sub-Total15
GRAND TOTAL46
ASSESSMENT OUTCOME:   ☐ Competent    ☐ Not Yet Competent (competent if at least 50%)
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🔒Set up and operate a forging heating furnace at 1200°CPractical 3
🔒Set up a forging hammer to deliver specified forcePractical 4
🔒Prepare and set forging dies for a mild steel componentPractical 5
🔒Set up rolling mill for forging a 1500mm long mild steel blankPractical 6
🔒Set up trimming machine for forged piecesPractical 7
🔒Calculate and set forging equipment parameters for a mild steel blankPractical 8
🔒Calculate and Set Up Ideal Work of Deformation for ForgingPractical 9
🔒Set forging process parameters considering friction forcePractical 10
🔒Set forging temperature parameters using heating furnace controlsPractical 11
🔒Set up forging tools for a 150mm x 50mm blankPractical 12
🔒Adjust forging equipment for optimal interface shear forcePractical 13
🔒Set up forging dies considering fillet volume for accurate forging shapesPractical 14
🔒Operate and Calibrate Trimming Machine to Finish Forged ComponentsPractical 15
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Am I competent?

At the start of this chapter we promised you would be able to:

  • safely and correctly check the condition of forging equipment by following the manufacturer’s manual
  • correctly mount the tools and accessories needed for your forging tasks
  • accurately set the forging equipment parameters according to the manufacturer’s instructions

Tick each one you can genuinely do.

So, are you there yet?

You're competent when you can confidently do 50% or more of what this chapter promised.

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← Ch 3: Prepare forging workpiece Ch 5: Perform forging operations →