Precision, Control, Safety: The Art of Manual Air Hammer Forging

During the die forging process, when machine hammering fails to meet practical requirements, manual operation of an air hammer becomes necessary. This is a highly skilled task demanding extensive experience. At Xingdao, we have summarized the core techniques for manual air hammer operation, aiming to enhance efficiency, guarantee quality, and ensure safety.

I. Holding Tongs & Rotating Material: Steady as a Rock

Tong Selection: Use long-handled forging tongs matched to the blank size. The jaw shape must firmly grip round steel or pre-forged blanks (e.g., flat-jawed pliers, round-nose tongs). The handle length must keep hands clear of the danger zone (at least 50cm from the hammer head).

Clamping Essentials:

Clamp near the blank's center of gravity or at a point facilitating controlled rotation.

Apply sufficient clamping force to prevent the blank from flying out during striking ("fly-off" is EXTREMELY DANGEROUS!).

Coordinate wrist, arm, and body movements to stabilize the tongs and minimize shaking.

Anticipating Deformation: Based on the deformation from the previous blow, anticipate the angle/distance needed for the next rotation or movement.

Utilizing Hammer Rebound: Use the moment the hammer head lifts to make swift, small, and precise rotational or translational adjustments. Movements must be decisive and fluid, avoiding hesitation.

Maintaining Blank Level: Always ensure the blank contacts the lower die face parallel to prevent misalignment or die damage due to uneven force.

II. Positioning & Placement: Precise as a Caliper

Visual Positioning: Quickly and accurately place the blank (especially pre-forged semi-finished parts) into the center of the die cavity. This requires well-developed spatial awareness gained through extensive practice.

"Three-Point Contact" Principle: Ensure stable contact between the blank and the die locating surfaces (e.g., stops, pins) or key forming surfaces before striking. Gently tap once during initial placement to confirm position.

III. Striking Control: Forceful yet Precise

Force Selection: Skillfully use the foot pedal or handle to control impact force:

Light Strikes (Tapping): Used for blank positioning, initial shaping, thin-walled parts, or final finishing in late-stage forging. Control the hammer head for small, rapid bounces.

Heavy Strikes (Full Blows): Used for rough forging requiring large deformation, pre-forging, or filling deep cavities. Allow the hammer head to momentarily "settle" or compact the material upon impact.

"Listening to the Sound to Assess the Shape": Experienced operators can judge metal fill and detect voids or folds based on the striking sound.

"Monitoring the Heat": Constantly observe the blank's color change (indicating temperature drop). Complete critical deformation before the temperature falls below the final forging temperature.

IV. Rhythm Control: Fast yet Orderly

Continuity: Ensure operations (placing -> striking -> rotating/moving -> striking) are continuous and compact, minimizing the blank's cooling time in air, while prioritizing safety and positioning accuracy.

Anticipation & Coordination: The left hand (holding tongs) must coordinate highly with the right hand (operating controls) or foot (pedal control), developing muscle memory. Keep eyes focused on blank deformation and die condition.

Of course, even the most refined skill must be built upon absolute safety awareness. Xingdao's air hammer operators are dedicated to continuous summarization and continuous improvement.