How to Make a Blacksmith Hydraulic Press

Hydraulic forging presses employ a strong mechanical force to shape metals. They're powered by piston and cylinder systems which create pressure in their hydraulic fluid reservoir.

An electric hammer allows smiths to perform many of the same tasks as its power counterpart, yet offers greater control and expands upon what can be achieved when working with hot metal.

Getting Started

A blacksmith hydraulic press can open up a world of opportunities in any blacksmith's workshop. It allows smiths to work with hot metal that would be impossible with power hammer alone and create pieces not possible through hand forging alone. This book explores both its history and usage in blacksmith shops; including comparisons between presses with other machines, what to consider when purchasing used or building new presses, as well as tooling solutions that will maximize their benefits.

When purchasing a hydraulic pump for your press, begin with GPM (gallons per minute) before determining how many PSI (pounds of force per square inch) you require for optimal pressing force. A double stage pump enables you to run at lower pressure for bending before switching over to higher pressure for forging operations.

To be effective, a forge requires having specific dimensions. While ready-made forges from vendors may save time and money in terms of assembly costs, building one yourself may provide greater savings over time.

Hydraulic Pump

Hydraulic pumps are at the core of every hydraulic system, providing hydraulic fluid that raises pressure to allow machines such as lifts, cranes, motors, and heavy machinery to pull, push, turn or expand. Furthermore, these pumps also serve as sources of power for industrial equipment like conveyors and mixers and are available in different sizes and shapes to meet different commercial application requirements. Selecting the appropriate pump requires taking into account operating specifications like maximum and continuous operating pressure levels, horsepower power source capacity requirements as well as maximum fluid flow rates to find one suitable for an application.

As hydraulic systems are pressurized, they must maintain consistent force over varying distances in order to transfer more power than similar mechanical systems of similar size and weight. Therefore, an ideal pump for any particular application would be one which could operate at high speeds with minimal loss in performance irrespective of load.

Hydraulic pumps come in various varieties: open center, axial piston, gerotor and internal gear. Axial piston pumps feature reciprocating pistons that move within their respective cylinders to create suction and discharge zones; open center pumps trap hydraulic oil between their gear teeth which allows the gears to mesh without needing sector elements as an intermediary solution.

Gerotor hydraulic pumps utilize the meshing action between internal and external gears to a create a hydraulic fluid circulation system. While they don't offer as high an efficiency rating as their internal gear counterparts, gerotors tend to have easier maintenance requirements due to shaft seals and wear plates being easier to keep clean than their axial piston counterparts.

Hydraulic pumps are positive-displacement devices and, like any positive displacement device, require overpressure protection in the form of a pressure relief valve for safe operation. The pressure-relief valve is usually built into the pump itself and can be adjusted to limit how much pressure is generated. Furthermore, touching or operating a running hydraulic pump while it is operating can be extremely dangerous; personal protective equipment must always be worn prior to starting and lockout procedures must be observed prior to using.

Hydraulic Cylinder

Hydraulic cylinders are integral parts of blacksmith forges, converting mechanical energy into power to drive their operation. There is a variety of hydraulic cylinders on the market with specific advantages and uses; some may be more energy-efficient while others offer greater reach or force. In order to choose an ideal model for you needs it's essential that you understand each characteristic before choosing.

Most hydraulic cylinders are constructed of metal and coated with hard chrome or paint for added protection from the harsh hydraulic fluid environment. Furthermore, this protective layer also prevents scratching or pitting that could compromise seal integrity or allow contaminants into the hydraulic system.

Hydraulic cylinders differ from pneumatic ones in that they utilize pressurized fluid to transfer power, enabling much quicker movement than would be possible using air pressure alone. However, keep in mind that as pressure increases within a cylinder's system so too does its force output.

There are two primary types of hydraulic cylinders-single acting and double acting. Single acting cylinders work in one direction-when hydraulic fluid is pumped into their barrel it will expand; external energy must then be used to generate a return force; this type of cylinder can often be found in forge hammers.

Double acting cylinders can both push and pull, making them useful in situations that require both extension and retraction. While one single acting cylinder could technically perform these duties, double acting cylinders tend to be more cost effective and convenient options.

Telescopic hydraulic cylinders are another common type. This style contains multiple interlocked cylinders nested within each other to give it greater reach than single cylinders of comparable sizes.

Tie rod cylinders are held in place by threaded or flanged tie rods of various lengths and types that come in various sizes to secure them to their bases. Tie rod style cylinders are often seen in industrial factory applications and tend to be smaller than their counterparts. Tie rods connect cylinder heads with bases; therefore they must be strong enough to withstand the tremendous force generated by hydraulic cylinders.

Anvil

An anvil may look like an immovable lump of iron with sharp points, but they are actually deceivingly sophisticated tools made out of various styles and materials. Blacksmiths need an anvil for shaping metal into different forms for different applications; therefore it must be of high quality with useful working surfaces for shaping metal into shape without deforming. Blacksmiths often hammer on an anvil's flat face to shape it as needed with heavy strikes without deforming; modern models often include hard steel plates welded onto their faces for extra strength; while other models feature slightly rounded faces to focus the force onto small areas on metal surfaces.

An anvil's horn is a flexible pointed end which can be bent into various round forms to facilitate bending processes. Constructed of unhardened iron or steel, its durability may differ from that of its face anvils; some even feature side horns for specific jobs.

Blacksmiths tend to use their hammers only sparingly in order to conserve energy, as direct contact would cause heat transference from anvil to what they are forging, which could slow them down significantly. Furthermore, they seek to keep both anvil and hammer warm by having brief touches between the two devices to avoid cooling the metal too rapidly.

An anvil must be at an appropriate height for its user. While its ideal height varies with size, generally speaking it should allow them to stand comfortably without straining. Some larger anvils come equipped with mounting options that make them even more stable.

An anvil can be expensive, but there are ways to find one at an affordable price. Engineering shops may be willing to give away scrap pieces of very thick and hard steel at no charge; otherwise Craigslist and garage sales offer great opportunities to find metal pieces with useful shapes and surfaces for free.