Types of Japanese Forging Hammers
Modern Japanese forging hammers are mostly pneumatic hammers. Many of them also employ mechanical linkages and elec tronic controls to enhance operator safety, precision and productivity. Here are some popular types:
- Big Eye Hammer: It employs an enlarged eye to create a variety of open dies. This hammer can forge dies weighing around 12,000 pounds. The hammer's dropped ram weights can be altered, as can the electronic controls that regulate the sleeve's drop and the ram's lifting and descent speed. For operator safety, the Big Eye hammer has a two-handed, touch screen electronic control that protects the operator's hands while alerting the operator with digital readings and alarms. Operating air pressure ranges from 90 to 100 psi, and it can create products such as crankshafts and trolley wheels.
- Open Die Hammer: This hammer can produce any shape and size of an object using a die of any shape. This hammer first heats the metal until it liquefies, then places it between the dies that are moving toward one another, forging the metal into any die shape. This hammer works with 3,200 cubic feet per minute of air and 100 psi to forge objects. The hardness of the material it can forge ranges from HRC 60 to 65, and it takes five to 20 pounds of hammer blows to forge each square inch of metal.
- Super Hammer: This hammer is bigger than the Big Eye hammer and can weigh up to 36,000 pounds. It can forge bigger dies, around 55,000 pounds. This forging hammer works at 3,200 cubic feet per minute and with 100 psi. It produces large equipment parts such as wheel hubs, axle boxes, ring gear blanks, and turbine rotors. The dual-sided hammer has a two-hand push button control for operator safety.
- Power Hammer: This heavy-duty hammer is bigger than an air hammer, is lighter, and forges many objects in different shapes and sizes. The power hammer forges metal by moving a weighted hammer head vertically in a guiding frame. The hammers can be powered electrically, pneumatically, or hydraulically. The power hammers can have single or double acting. The single-acting power hammer only uses one cylinder filled with pressurized air to move the hammer downwards, while the double power hammer uses one cylinder to move the hammer down and another to return it to its original position using gravity and pressurized air in both ways.
Maintenance of Japanese forging hammer
Application of proper maintenance techniques ensures the reliability and useful lifespan of the Japanese power hammer and forging hammer. The maintenance tips below can serve as a reliable manual for hammer care.
- Regular Cleaning: Regular cleaning should go beyond the surfaces of the hammer. Critical areas where dirt and grime tend to accumulate also require cleaning. These areas include the cooling fins, ventilation grilles, and any intricate parts of the hammer. Power washing is not an option, as it can damage delicate electrical components. Rather, use compressed air to blow out the dust in hard-to-reach areas of the hammer.
- Lubrication: Lubricating the moving parts of the hammer boost its performance and reliability. This is because it reduces wear, friction, and even overheating. Manufacturers usually indicate the recommended types of lubricants for specific components of the hammer. Following their suggestions usually brings about optimum results. Apart from the specified lubricants, hammer owners can also use high-quality machine oils and greases.
- Regular Inspection: Frequent inspection of the hammer reveals potential problems. Discovering issues like abnormal wear, leaks, and loose parts early enough helps to prevent costly downtimes and extensive repairs. Owners and operators of the forging hammer must develop a routine inspection schedule. During routine inspections, it is necessary to pay attention to critical components like hydraulic seals, electrical connections, and air hoses.
- Respecting Hammer Capacity: Each forging hammer has its capacity limits. Sticking within the recommended capacity helps to prevent premature wear and over-exertion of the hammer.
- Regular Professional Servicing: Although hammer maintenance depends significantly upon the user and operator, there are professional services that can improve the hammer's performance. These professionals possess the knowledge and experience to handle the hammer properly. They know the right techniques to adopt to preserve the integrity of the hammer. With their skills, they can identify the servicing needs of the hammer. Their regular servcing helps to prolong the hammer's life.
In summary, taking proper care of the Japanese forging hammer can improve its use and extend its lifespan. The maintenance techniques discussed here can apply to different types of hammers.
Usage scenarios of Japanese forging hammers
Due to its exceptional strength and flexibility, the Japanese forging hammer is used in distinct industries and crafts. Here are some usage scenarios of this machine:
- Blacksmithing: Blacksmithing remains the primary usage scenario of Japanese forging hammers today. These machines are used to shape and refine metal into various objects, such as tools, weapons, and hardware. The controlled force and precision of Japanese forging hammers are perfect for delicate tasks like shaping blades, creating intricate designs, and forging ferrous and non-ferrous metals.
- Jewelry making: A smaller version of the Japanese forging hammer, the jewelers' hammer, is popular in the jewelry industry. During jewelry creation, the hammer can shape metals, resize rings, and impact metal with intention and control. The machines strike smaller metal pieces with precision.
- Architectural and artistic metalwork: Forging hammers are commonly used in creating architectural metalwork, such as gates, railings, and358 chandeliers. They are also employed in sculptural and artistic projects involving metal manipulation and forging. The hammers enable artisans to add aesthetics to their pieces by creating textured surfaces, shape unusual forms, and combining different metal sections.
- Restoration and repair: Japanese forging hammers play a vital role in the restoration and repair of historical artifacts, monuments, and buildings. These machines are helpful in working with old metals, such as bronze or copper. They are also used to restore damaged metal components like sculptures, gates, and decorative elements.
- Meet the demand for small production: Japanese forging hammers can be used for repeated production of small quantities with comparatively fewer workers. In this scenario, the hammer increases productivity while maintaining attention to detail in the craftsmanship.
How to choose Japanese forging hammers
The Japanese forging hammer is designed using durable steel material in the frame and anvil. The frame is secured after hard welding to prevent breaking. Gears are designed to handle reverse rotation to avoid wear and tear over time.
CNC machines produce precision parts to streamline the assembly process. A power source, such as the air compressor, forms the driving unit of the hammer. It must be of the right capacity to deliver sufficient air pressure.
The anvil of the hammer is strike-shaped because it offers metal work pieces unique forms. Metal workers can create products with rounded, flattened, and grooved features. The anvils also have a hole called the ‘anvil eye,’ which supports various forging operations—dies and anvils undergo forging and casting techniques to achieve diverse shapes.
The hammers come in different weights. Heavy-duty hammers are ideal for working with large and heavy metal pieces, while light-duty hammers are suitable for lighter ones. Customers prefer light-duty forging hammers because they are easy to handle.
Industrial plants and metal manufacturing companies will use extra-large hammers with air compressors of at least 6-8 CFM. The average air compressor capacity for smaller machines is 2-4 CFM. Heavy-duty machines are classified into 10 HP, 15 HP, and 20 HP. Smaller categories of the air hammer include the Japanese air forging hammer or air compressor hammer machine. It forges metal via air pressure and is suitable for personal use or smaller production lines.
The forging hammer's blows per minute range start from 800 to 1,200 and higher, depending on the machine's size and capacity. Industrial-scale forging hammers produce fewer blows because they have more intense hammering power. Smaller hammers produce more blows per minute because they have lighter striking weights.
Q&A
Q: What are modern Japanese forging hammers used for?
A: Modern Japanese forging hammers are used for a wide range of applications, including aerospace engineering, automotive manufacturing, medical device production, and high-precision machining. These heavy-duty instruments remain essential in creating quality parts and materials.
Q: What are the advantages of Japanese forging hammers?
A: Japanese forging hammers offer several advantages, such as high energy efficiency, precision control of imparted energy and mass, uniform deformation of metals, and reduced material waste. They also have faster production rates than other forging methods. This makes them cost-effective for large-scale manufacturing.
Q: What are the types of Japanese forging hammers?
A: There are several types of Japanese forging hammers, each with its unique working principle and features. These include:Crank-Type Hammers; Pneumatic Hammers; Hydraulic Hammers; Double-Flywheel Hammers; Steam Hammers; Sledge Hammers; Hand Hammers
Q: Do Japanese forging hammers require special maintenance?
A: Yes, to ensure optimal performance and longevity, it is important to follow manufacturer guidelines and schedule regular inspections and repairs. With proper care and maintenance, these heavy-duty instruments can last for many years.
