Unit 4. FORGING (Ковка)

Starting up:

•What associations do you have with the word “forging” (ковка)?

•Do you possess any forged things? How do/can you use them?

•What are the traditionally most common tools for forging?

Text “Forging and Forging Operations”

Study the vocabulary:

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Exercise 4.1. Read the text. While reading, fill in the table.

Metal Forging is the process of shaping a piece of metal using continuous pressure, often used to tool steel or iron. The extreme pressure may require rolling, pressing, or hammering the workpiece to shape it into the desired part.

Forging Processes: Hot Forging vs. Cold Forging

A wide range of metalworking processes is available to forge parts. The type of forging depends on the specifications of the part and the requirements for the production run. Most metal forging involves the use of extreme heat to soften the metal. With hot forging, the metal may be heated up to 1150°C.

As the metal is more pliable, less pressure is needed to form the metal. After pressing the material, it cools and hardens. The finished part is often much stronger compared to its original form. However, hot forging provides less tight tolerances compared to cold forging.

With cold heading, the metal is not heated. It is formed near room temperature, which makes it better suited for working with softer metals. The main benefits of cold forging include faster production rates and increased interchangeability.

Common Forging Methods

Drop forging is the process of dropping a large hammer onto the heated metal to form it into the shape of a die. Some dies are molds with distinct shapes while others are flat surfaces. The two most used methods of drop forging are open-die forging and closed die forging.

With press forging, a press is used to apply force instead of a hammer. The press travels at a slower speed compared to the hammer, allowing it to reach deeper into the material. The metal workpiece is affected uniformly.

Compared to drop forging, press forging provides many useful benefits. It offers greater accuracy and capacity, making it suitable for large parts.

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Some presses are automated, which reduces labor and overall costs. It is also a more economical solution for high-volume production runs.

Roll forging is another forging process, mostly used to produce steel bars and long parts. The forging process involves two cylindrical rolls that deform a bar stock. The heated material passes through the cylindrical rolls until the desired shape and size are achieved. This generates less material waste compared to some drop forging methods and allows for favorable grain structure.

Closed Die Forging vs. Open Die Forging

Traditional smith forging is a type of open die forging. This process requires the workpiece to be placed between two surfaces, such as an anvil and a hammer. The hammer strikes the workpiece to form it.

Modern open die forging often involves the use of two dies. The workpiece is sandwiched between the dies but is never fully constrained. Advantages of choosing open die forging include: continuous grain flow, reduced chance of defects, increased strength and fatigue resistance, finer grain structure.

What is the best metal for forging?

It’s possible to forge any kind of metal, but there are certain metals and alloys that are better suited for different applications. Most commonly, these are the kinds of metals that get forged: сarbon, alloy, and stainless steel, exceptionally hard tool steels, aluminum, titanium, brass and copper, hightemperature alloys containing cobalt, nickel, or molybdenum.

What are the characteristics of forged products?

Forgings are needed where strength, reliability, economy and resistance to shock and fatigue are vital. Forgings can be produced from the materials possessing ductility, hardness, machinability at different temperatures. Forging develops the maximum strength potential of a material recrystallization of the material and further grain refinement produces extremely uniform material with optimum response to heat treatment. During the forging process the material obtains the fibrous structure and does not change its state. Heat resistance, corrosion resistance, hardness, strength, resistance to creogenic temperatures, magnetic or non magnetic properties are almost certainly available in forging.

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What items can be done by forging?

Forgings are normally component parts contained inside assembled items of airplanes, automobiles, ships, oil drilling equipment, engines, missiles, and all types of capital equipment – to name a few. The artistic forged items are numerous and include iron fences, stairs, balconies, visors, garden forging, iron gates, doors, grills, gazebos, iron fittings, furniture including loft furniture, lighting, works of arts, etc.

After-reading tasks:

Exercise 4.2. Complete the sentences according to the text:

Professional Language Development

Exercise 4.3. Explain the meaning of the words and word combinations from the text:

interchangeability, distinct shape, flat surface, vital, fibrous, cryogenic, loft furniture.

Exercise 4.4. Match the words with their opposites. Make 8 sentences of your own with the words.

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Exercise 4.5. Translate the sentences into English.

1.На лекции нам рассказали о горячей и холодной обработке металлов.

2.Ковка – это процесс изменения формы металла под воздействием удара или сжатия.

3.Холодная ковка – это пластическая деформация при комнатной температуре.

4.Горячая ковка – это пластическая деформация при температуре выше точки кристаллизации.

5.Сжатие обрабатываемой заготовки между плоскими бойками является основным процессом деформации металла.

6.Некоторые бойки имеют плоскую поверхность, в то время как другие имеют выпуклую форму.

7.Более узкие бойки могут быть использованы для удлинения (rolling) заготовки.

8.Чем более податливый для ковки металл, тем меньшее давление нужно применять.

Grammar Focus

The Objective Infinitive Construction

(Объектный инфинитивный оборот) or Complex Object

Study the table and pay attention to how the Complex Object construction is translated into Russian:

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Дополнение + инфинитив = объектный инфинитивный оборот (Complex

Object). Дополнение выражено существительным в именительном падеже или местоимением в объектном падеже (me, you, him, her, us. them)

Объектный инфинитивный оборот (Complex Object) используется после

следующих групп глаголов:

•verbs of mental activity – to think, to consider, to suppose, to believe

•verbs of wish, likes and dislikes – to want, to like, to hate

•verbs of order and permission – to ask, to tell, to order, to offer, to enable

•reporting verbs – to say, to report, to announce

He wants me to finish the work as soon as possible. . – Он хочет, чтобы я закончил работу как можно скорее.

My friends expected the trip to last longer. – Мои друзья ожидали, что поездка продлится дольше.

He asked you to clarify the data. – Он попросил вас уточнить данные.

Инфинитив употребляется без частицы to после глаголов:

1.to make, to let

2.глаголов сенсорного восприятия to see, to hear, to watch, to notice, to observe:

I saw someone come into the room. Я видела, что кто-то вошел в комнату.

We heard them have worked out a new technology of welding. Мы слышали, что они разработали новый вид сварки.

They made me continue my work. Они заставили меня продолжать работу.

Let him complete the experiment on his own. Пусть он (позвольте ему)

закончить эксперимент самостоятельно.

Exercise 4.6. Translate the following sentences with the Complex Object into Russian:

1.We watched the plane land. 2. The climate of England is considered to be mild and humid. 3. He is ordered not to be late. 4. I found your story to be very interesting. 5. If you want us to make the work quickly you should let us start it at once. 6. She felt somebody touch her hand. 7. Don’t let them play in the street. 8. I expect you to arrive on time. 9. Don’t make me laugh.

10.The teacher advised us to use dictionaries.

Exercise 4.7. Fill in the particle to where needed:

1.I want her (learn) English. 2. That is too difficult for you to do, let me (help) you. 3. Would you like me (do) it today? 4. Please let me (know) the

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results of the test as soon as you know it. 5. We allow the students (use) dictionaries at the exam. 6. We expected our faculty team (win) the competition.

The Subjective Infinitive Construction (Субъектный инфинитивный оборот) or Complex Subject

Study the table and pay attention to how it is translated into Russian:

Сообщают, что инженеры работают над новым станком.

Подлежащее + инфинитив = субъектный инфинитивный оборот (Complex

Subject)

В составе Субъектного инфинитивного оборота сказуемое может

употребляться в а) страдательном залоге или б) действительном залоге. а) после глаголов:

•to see, to hear, to notice (verbs of sense perception)

•to think, to consider, to suppose, to believe (verbs of mental activity)

•to ask, to tell, to order, to offer (verbs of order and permission)

•to say, to report, to announce (reporting verbs)

He was seen to be talking to his friend. Видели, как он разговаривает со своим другом.

Water was supposed to be an element. Было сделано предположение, что вода – это элемент.

The explanation is considered to be convincing.Это объяснение считают убедительным.

The delegation is reported to have left the city. Сообщают, что делегация уехала из города.

b) после глаголов:

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He seems to know the rule well. Похоже, он хорошо знает это правило.

Your advice proved to be helpful. Ваш совет оказался полезным. They are likely to come here. Вполне вероятно, что они придут сюда.

The acid seems to be able to dissolve this metal. Эта кислота, по-видимому,

способна растворить этот металл.

Exercise 4.8. Translate the sentences with the Complex Subject into Russian:

1. She is said to know some Oriental languages. 2. The water seems to be boiling. 3. He was said to have been travelling a lot. 4. I am unlikely to win the competition. 5. He is sure to return soon. 6. They are reported to have left the city two days ago. 7. They weather appears to be improving. 8. I happened to be there at that time. 9. They are likely to arrive soon. 10. The plant is known to produce electronic circuits.

Exercise 4.9. Translate the parts of the sentences in brackets into English:

1.Extreme heat (известно) to be applied in order to soften the metal.

2.Less pressure (вероятно) to be needed to form the metal.

3.The finished part (предполагают) to be much stronger compared to its original form.

4.The main benefit of cold forging (похоже) to be its lower cost.

5.Press forging has (было доказано) to be much more accurate compared to drop forging.

6.Any kind of metal or alloy (маловероятно) to be forged.

7.Less material (предполагают) to be wasted compared to drop forging methods.

8.The most suitable metals for forging (оказалось) to be carbon, steel, etc.

Exercise 4.10. Read the sentences. Divide them into two groups: the sentences with the Complex Object and the ones with the Complex Subject. Translate into Russian:

(Upsetting is the process of hammering the end of a heated bar of metal so that its width is increased locally, as in the manufacture of bolts)

1. The method of upsetting is said to be the best one. 2. I want him to give a presentation on the latest trends in metal processing. 3. I heard the professor speak about upsetting. 4. The teacher asked the students to talk

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about the fundamentals of upsetting. 5. This method of upsetting is sure to have some advantages. 6. The students wanted the teacher to give some additional information about the new way of metal processing. 7. The young specialists were known to be working at the problem of continuous upsetting. 8. His knowledge of the upsetting process proved to be both deep and many-sided. 9. Many various types of upsetting machines are reported to have been produced at our town plants. 10. Upsetting is known to be used for reshaping metal by plastic flow. 11. The engineers were asked to develop some new improvements to the technology of upsetting. 12. The researchers are known to have used this technology for many years.

Exercise 4.11. Read the text. Find the sentences with the Infinitive and define the function in each case. Find the sentences with the Complex Object. Translate them.

Art Forging Techniques

Elegant metal products are created to decorate any interior. The hot forging method involves heating the metal to an extreme temperature to change its shape. Forgers make metals create exclusive curls, waves, incredibly beautiful patterns. The cold technique is known to be used with the metals like gold, silver, copper, aluminum, other non-ferrous and precious metals. The process requires additional equipment – presses, special machines, hammers.

Stamping is used to make a desired form on a metal sheet part. Metal samples are placed in special templates which are then heated or pressed. It all depends on which stamping the blacksmith chose – hot or cold.

Many techniques are used by professionals to provide high-quality metal processing. These include hood, draft, chopping, punching, bending and other methods.

The most popular forging styles are considered to be: Romanesque – it is characterized by massiveness, monumentality and symmetrical, repeating patterns. Gothic – it is lancet arches, peaks, the strict geometry of typical rosettes and cruciferous. Renaissance – spirals, various artistic curls, the use of a round bar and the addition of cast elements to the decor. Empire and classicism are laconicism and simplicity of forms combined with solemn elegance. In the Art Nouveau style, original metal elements with ornaments are often forged. It is characterized by the absence of straight lines, the expressiveness of forms. Using the futuristic art deco

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style, craftsmen combine different metal forging technologies to achieve the most impressive results.

Exercise 4.12. Answer the questions:

1.What is the hot forging method used for?

2.What equipment is needed for the forging works?

3.What temperature conditions are needed for stamping?

4.What is the difference between the terms “style” and “method” of forging?

5.In your opinion, what metal objects and items are typical for the different styles in art?

6.What are the main features of each of the styles in metal working?

Speaking

Make a dialogue with your partner. In the dialogue prove the importance of metal forging. Use the facts you may have obtained during your lectures at the university, specialist magazines and Internet sites.

Read the poem and translate it into Russian:

Under a spreading chestnut tree The village smithy stands;

The smith, a mighty man is he, With large and sinewy hands; . . .

Week in, week out, from morn till night, You can hear his bellows blow;

You can hear him swing his heavy sledge, With measured beat and slow, . . .

Thus at the flaming forge of life Our fortunes must be wrought; Thus on its sounding anvil shaped Each burning deed and thought!

— Henry Wadsworth Longfellow

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