Business plan: artistic forging. DIY artistic forging

Admiring the beauty of an openwork metal fence or admiring the incredible twisted pattern on the railing of an iron staircase, few people think that they were made using the cold forging method. You can learn to embody beauty in metal without much effort. To do this, it is enough to have minimal skills in working with metal and have special machines for cold forging.
What is cold forging? What machines are needed for it? What can be made on these machines? You will find answers to these questions in our article.

It would be more correct to call cold forging - mechanical bending of a metal rod on specialized machines to give it the shape intended by the manufacturer. Bending rods in the machine can be done either manually using levers or using electric motors. In addition to metal rods, cold forging can be used to bend small-diameter pipes, narrow iron strips and fittings. Using the cold forging method the following are produced:

• Twisted fences.
• Decorations for residential buildings.
• Patterned gate.
• Railings for balconies and stairs.
• Metal garden benches.
• Decorations for gazebos and lanterns.
• A large number of grating options.

Elements made by cold forging
Having mastered the cold forging method, you can easily start your own business producing metal products. At the same time, you will only need initial financial investments for the purchase of machines, and if you make the machines yourself, you can get by with minimal costs.

Below we will give you instructions on how to assemble cold forging machines yourself.

Machine "snail"

Making a snail machine is one example of independent design, and it makes no sense to give advice with an exact indication of the dimensions of all parts. You need to be guided by your idea of ​​​​the operation of the machine, how and what will bend, how many turns of the spiral will be enough for high-quality work, what size the lever with the tabletop will be. If you understand the essence of the machine manufacturing process, then the assembly itself will not cause any particular difficulties.

Machine “snail”

Manufacturing of main machine components

Frame.

The process of bending an iron rod exposes the machine to heavy loads, so when making the frame for the “snail”, only a metal corner, channel or thick-walled pipe is used. Do not make a frame from wooden beams; such a table cannot withstand prolonged loads and collapses.

Tabletop.

The tabletop for the “snail” is made of a metal plate cut in the shape of a circle, at least 4 mm thick. From the same slab, a second tabletop is cut out, repeating the shape of the first. The snail segments will be placed on the second tabletop and the products will be bent. During the cold forging process, the tabletop takes on the bulk of the load, so there is no need to save money and make it from a thinner sheet of iron.

Main shaft and lever.

The main shaft is placed centrally between the tabletops and is attached to the base using four right triangles. The shaft can be made from a thick-walled pipe of the required diameter.
The lever is attached to the shaft using a ring and rotates around it; in addition, a roller is installed on the lever for bending the rods on the upper tabletop.

Machine diagram

Marking and installation of attachments

Depending on whether you want to produce only the same type of samples or you need more artistic products, there are three options for the snail device.
Option #1.
This is the simplest of the three options; its essence is that the outline of a spiral is drawn on the tabletop.

Drawing of the snail segments
At its core, this is a drawing of future products that you will produce on the machine. After applying the diagram, it is enough to cut out several segments from thick strips of iron of different widths that follow the line of the drawing and weld them to the tabletop according to the markings. With such a static “snail” you can make simple bends.
Option #2.
The second option is the most popular among homemade machines; it involves making a collapsible snail from removable parts. Holes are drilled along the contours of the markings into which threads are cut. Next, templates for the stop segments are made from cardboard or plywood and metal overlays are made from them. Finally, holes are drilled in the pads, which should coincide with the mounting sockets on the countertop. To secure the segments, bolts are mainly used, but you can also make cylindrical stops. This “snail” design will allow the production of spiral-shaped workpieces with different radii on one machine.

“Snail” made of metal strips
Option #3.
In the third option, instead of collapsible stop segments, several removable modules are made with different volute options, which change as needed. The module is made of a piece of iron onto which segments repeating parts of the spiral are welded.

Snail modules
Machine assembly.

1. Install the frame in a place where you will have easy access to the machine from all sides.
2. Concrete the legs of the frame in the floor or secure the frame in another accessible way.
3. Weld the main table top to the frame.
4. Install the main shaft by welding it to the tabletop and strengthening it with triangles.
5. Place the rotating lever onto the shaft.
6. Install the top tabletop by welding it to the main shaft.
7. Place the snail segments on the tabletop.

After assembly, test bend the rod.
To learn more about assembling a snail cold forging machine, watch the video:

Torsion bar machine

This machine is designed for uniaxial longitudinal twisting of a workpiece from a transverse or square rod.

Torsion bar machine
A channel or I-beam is used for the base of the torsion bar machine. A thick iron strip is attached to it by welding, onto which a vice is installed to clamp the stationary part of the rod. The vice is secured with four bolts with a diameter of M16 or more. To increase the strength of the clamping of the rod, corrugated sheet steel plates are welded onto the vice. On the opposite side of the base, guide rollers are installed, to which a clamping unit for the movable part of the workpiece is attached. It is made of a steel bushing, in which it is necessary to provide holes for clamping bolts located at an angle of 120 degrees. The bolts must have a flat end and be made of high quality steel. Both clamping devices must be positioned coaxially; to do this, they must be checked using a level, a plumber's square and a caliper.

Types of machines
Next, you need to make a handle for turning the moving part of the clamp. Its lever should hit as long as possible to reduce the applied force. It is better to make the handle itself with a rubber bushing to prevent the hand from slipping during operation.
After the machine is fully assembled, it is checked for the reliability of the moving elements and the accuracy of the deformation of the bar. After checking, the machine is attached to the support frame.

A simple model of a torsion bar machine
How to make a torsion bar machine with your own hands, watch the video:

Gnitik machine

To qualitatively form a corner in a product produced by cold forging, you will need a machine called a “bend”. It consists of a steel plate with a movable stop on which there are two support shafts and a lever.

Machine “gnutik”
The workpiece is placed between the wedge and the support shafts. After this, with the help of a lever, the wedge is shifted towards the shafts, which leads to bending of the workpiece.

Computer model of the machine
Making such a machine is quite simple, the main thing is to follow the given drawing and use tool steel, since during operation a large load is placed on part of the device.
You can also watch how to make a “gnitik” machine in the video:

Wave machine

It would be more correct to call this machine a controlled wave. The equipment of the machine consists of a pair of steel disks with a diameter of 140 mm, which are bolted to the worktop. The axis of rotation of the universal wrench is fixed to the drive disk.

Machine “wave”
Wave control occurs as a result of changing the distance between the disks. When the bar is rolled around the drive disk with a knob, a pattern is formed, after which the bar is removed from the conductor and a pattern is formed on the other side.
You can watch the machine in action in the video:

Press machine

A press is needed to form the ends of the rods. This machine works on the principle of a flywheel; first, by rotating the bar with weights, the screw striker is pulled back until it stops. After this, a replacement stamp is inserted into the slot and the workpiece is placed. Next, quickly spin the bar in the opposite direction and leave it to rotate freely. Finally, the striker hits the stamp shank strongly, due to this, a force sufficient for stamping is developed.

Rolling press
As for the manual rolling mill, you can make it yourself, but you still have to order special steel rolls, bearing bushings and shafts, and buy gears in the store. Only “crow’s foot” and “leaf” tips can be produced on such a machine.

Connecting and painting parts

Elements produced by cold forging are connected in two ways:

• Welding - the parts are welded to each other, and the scale is ground off with a grinder or other grinding machine.
• Clamps - this type of connection looks much more beautiful. For clamps, stamped strips of metal with a thickness of 1.5 mm or more are used.

Finished products are painted using blacksmith enamels or acrylic-based metal paints.

Connecting parts using welding

Products produced by cold forging

We invite you to familiarize yourself with the options for products that you can make using the cold forging method:

As can be seen from all of the above, the cold forging method does not require large financial costs and is quite easy to learn, so if you decide to start learning blacksmithing with this method, then you did the right thing.

I did this about 6 years ago. I hope I don’t have to anymore. They looked for the customer through advertisements in newspapers and on doorsteps. There is a lot of movement from here, the production itself makes up a small part. I explain, the majority of customers did not want to come to our workshop due to their busyness and made an appointment immediately for to the object, you bring photographs, you explain with your fingers, you take measurements, you say an approximate price, the customer promises to think and call back, he calls back 30 percent, and you spent half a day and 10 liters of gasoline as a result and did nothing. Then the one who called begins to actively bargain (he didn’t just call you) and says that he is ready to place an order if I drop another 10 percent lower than the competitors. Whether they agree or not depends on the availability of orders. If you agree, you need to go to him again to sign the contract and receive an advance payment (again, time and gasoline). Then it is not always available the required metal, you begin to purchase the missing one. Then manufacturing (the most pleasant moment). Then installation, there are many problems, I’ll list some, power the welding machine, friendly neighbors from above, when installing gratings and a canopy on the ground floor, think that now thieves will walk along this grating every day. and they start yelling obscenities, but this is nothing compared to having water poured on your head and calling the police, even while welding, your neighbor’s computer may glitch and he will demand to buy him a new one, you have to send another one, often people converted apartments into shops without having them in hand permits begin installation, neighbors knock on government agencies, some kind of supervisor comes in paired with a district police officer and begins to find out who they are, where is the contract, here is the contract, but there are no labor agreements for the workers, fuck off, come here. Then you hand over the work and the customer says there is no money, wait, there is plenty there won’t be a chance. And this is not counting the problems with opening the workshop, I formalized everything I knew, it took a year, the check comes: there is an emergency, there is an emergency service, there are firefighters, it is agreed with the consumer market management, it is agreed with the executive committee, and where do you say the environmental assessment of your enterprises, I say nah, and they show me the law according to which it is necessary. Again, you take out of your pocket what you just earned and give it back.

My advice is to try it if you want, but keep in mind that this market is very crowded. Good luck.

Dear, it’s crowded in any market. Take for example Euroset and Skyron. Who is talked about more, who is the sales leader? It all depends on your ambitions and ability to pursue your interests. Don't scare the person at the initial stage. Yes, there are many nuances in this business, but other types of activities are also full of obstacles. And as they say: if you want less competitors, choose the most difficult path!

Business idea: cold forging of metal products
Where we do business from: garage, territory of a private house
Main costs: purchase of equipment
Necessary equipment: welding machine, cutting machine, vice, drill
Consumables: metal, varnishes, paints
Initial capital: no more than 30,000 rubles.
Payback period: several months
Possible profit: 50,000 rub. per month

A business idea based on cold forging of metal products. This idea can be classified as a business with small financial investments; at the initial stage, you will only need skill and no more than 30,000 rubles.

At the initial stage of organizing this business, it is better for you to learn for yourself all the intricacies of manufacturing cold forged items. To start, you will need a room that can be used as a garage or area near a private house. Also a set of equipment:

1. Welding machine
2. Grinding machine (grinder)
3. Vise
4. Drill, drilling machine
5. Other small instrument

The main skill will be the ability to use a welding machine.

Once you become familiar with cold forging, learn how to make simple items, and perhaps find your first clients, you can purchase an additional set of bending equipment that will help you make complex items. The cost of such a kit is about 55,000 rubles. This kit will help you make complex objects, make bends of the same shape at the same angle, and many other useful things.

Basic decorative elements are purchased separately. Such elements include: flowers, peaks, monograms and others. All you need to do is weld them to the finished product, then clean the weld seams with a grinder and paint the product in the desired color. The main color in which products are painted is matte black, but the ability to work with paint will help you create truly unique products. By mixing paints, you can achieve the color of aged bronze or copper, which will give your product some special character.

Cold forging, unlike hot forging, gives many advantages and allows you to produce unique products, such as fences, gratings, fences, canopies, flower beds, door hinges, accessories for fireplaces, , smokehouses, chandeliers, candlesticks, figurines of people and animals as decorative elements and much more.

Find a good supplier of decorative elements, usually a good supplier will have over 1000 different elements.
The final price for metal cold forging products consists of the cost of raw materials, the complexity of the work, the resources spent (fuels and lubricants, electricity), plus 100% of your work. That is, the profitability of a cold forging business is at least 100%.

How can you realize your abilities?
At the initial stage, it is better to take a training course, at least self-training in forging. If your city has forging courses, or, in extreme cases, welding courses, take them. If there are no such courses, then study on your own. Surely in your city there are already companies that produce forged products; offer them your services as an independent craftsman, in case of a large number of orders. It will be good if you are offered a job, you can study and at the same time receive money; forging masters earn an average of 40,000 rubles. per month, with such an income, you can save up for a good set of equipment. When working in a company, keep in mind the main goal - to create your own company for the production of forged products.

Sales of cold forging products.
As a rule, all products are made to order according to individual wishes and sizes, so making products for sale is not the best option. It will be better if you start looking for clients. Which you can see in the faces of the owners of country houses. These are the main clients.

Legal entities can also become good clients, this is the design of cafes, restaurants, bars, the exterior design of buildings, from gratings to porches.

To summarize, we can say that the business of cold forging of metal products is not devoid of a creative process, not in the actual production of objects, but also in the options for selling finished products. Based on this, the conclusion suggests itself - the more creative abilities you have, the more you can achieve in this business. Happy forging!

Ideas for Business from the section:

The constant technological progress inherent in modernity is gradually displacing from our lives handicraft (manual) production and crafts that have come down to us from our ancestors.

But cold forging can undoubtedly be classified as a craft that not only maintains competition, but is also gaining increasing popularity.

Forging elements are actively used:

• in the construction and design of country houses, residential premises and offices,
• in the production of furniture products,
• in the funeral business.

It is very difficult to imagine the exterior of a modern building without beautiful wrought iron grilles, gates and gazebos. Due to this cold forging products are in great demand and relevant. This is one of the main factors that budding businessmen pay attention to.

Forging combines art and ancient craft, thanks to which the cost of products is assessed not by the cost of the material, but by the complexity and beauty of the created structure.

Thus, the sale of finished products or the provision of cold metal processing services to the population is a very profitable and promising line of business for beginners.

Features of production organization

Forging is usually associated with traditional blacksmithing, where metal is manipulated after it has been heated. Such forging requires special training and a certain level of skill from the blacksmith, which is honed over the years.

The process of “hot” forging is very labor-intensive and time-consuming: the metal is heated in special furnaces until it becomes “soft” and with the help of hammers, a press and other devices it is given the desired shape, after which the part is cooled.

Today, cold forging technology has gained popularity..

Craftsmen process metal using special equipment, so the process takes less time, and the finished products are much cheaper for customers.

It is much easier to master this technology, which is attractive for beginning entrepreneurs. However, according to reviews from professionals, the cold forging business has its own specifics, which should be taken into account when organizing the business.

Market analysis and competition

Before starting any business, it is necessary to analyze the sales market, determine consumer preferences and identify the level of competition. However, cold forging products do not fall into the category of essential goods, which complicates the solution of these problems.

In the process of determining the need for forged products the following points need to be clarified:

• The number of workshops and forges that are already operating in your region.
• What is the demand for forged products and in what volume?
• Where can you sell your products?
• Determining the seasonality of business.
• What price category product will satisfy user needs?

Once the answers are received, entrepreneurs will be able to make a final conclusion: is it necessary to start a cold forging business in your area?

Mastering technology

Without special knowledge and skills, it is difficult to organize a cold forging workshop.

An entrepreneur will be very tempted to hire an experienced specialist, but at the initial stage of the business this is not recommended, since he will need to pay a large salary and you will be very dependent on him.

Therefore, before starting a business, a businessman will need to undergo training himself. Theoretical knowledge can be gained even through the Internet: there is a lot of information on the Internet on artistic and cold forging technologies.

However, in order to learn how to cold metal work, you need practice:

• You can get a job as a production worker or become an apprentice to one of your competitors.
• An experienced professional should only be hired if there is no other choice. But even in this case, be sure to agree with the master that he will teach you his craft.

After the entrepreneur goes through the training process, he needs draw up a detailed business plan for the implementation of your idea. In this case, it is necessary to use the information obtained in the process of market analysis and training.

The success of a business will depend on how well the business plan is drawn up and how accurately it is implemented.

It is worth noting that in some regions of Russia there are programs for state subsidies for small businesses, and financing of the idea is carried out on the basis of a business plan.

What will you need at the start?

Practical steps to organize any business must begin with state registration. The procedure is described step by step in the law “On State Registration of Legal Entities and Private Entrepreneurs”. In accordance with the law, a person engaged in entrepreneurial activity and receiving a permanent income must register as an individual entrepreneur or LLC.

Selecting a room

The room must first meet all fire safety requirements. The minimum workshop area should be 20 square meters. m. In addition, electricity must be installed.

An insulated garage can be an ideal place for a workshop. It is worth making sure that production noise does not disturb the inhabitants of nearby residential buildings.

The cold forging process involves welding, which cannot be done in a small enclosed room. In addition, you will need a place to store finished products. For these purposes it is necessary to organize a canopy at the workshop.

An entrepreneur must ensure that the premises had a wide access road for trucks. Otherwise, the process of unloading raw materials and loading finished products will become more difficult.

Equipment and tools for the workshop

It is impossible to imagine a cold forging workshop without special equipment and tools. One of the main expense items is investment in fixed assets.

At the initial stage for manual cold forging you need:

• Welding machine.
• Gnutik, used for bending metal. It is the main tool for cold forging.
• Wave. Serves to give the metal a wave-like shape.
• Snail. It will help to give a spiral shape to metal rods.
• Twister. Used to twist a metal rod around an axis.
• "Flashlight", which is one of the varieties of twister.
• Crafting table, with a vice.
• Bulgarian.
• Grinder for cleaning the surface of metal structures.
• Hammer, which may be needed when installing finished products.

At the initial stage, this equipment will be sufficient in the workshop.

The most famous brands on the market that produce high-quality equipment are the German Eizenkraft and Metalkraft.

The process of making curls using the cold forging method using a snail, see the video:

Purchase of raw materials

For that, To save time and not miss an urgent order, you should stock up on raw materials in advance.

The cold forging process uses:

• Low carbon steel blanks.
• Various metal profiles: square, sheets, corners, rods, etc.
• Auxiliary components: anti-corrosion paint, primer, solvent and electrodes.

It is necessary to purchase raw materials from trusted suppliers, which can also be found via the Internet. In this case, it is worth paying attention to the consistency of price and product quality.

Product range

Ideally, a cold forging workshop should work to order, because in this case there is no need to sell the goods.

However, for new entrepreneurs, especially if there is a lot of competition in the market, it is difficult to get an order. That's why at the first stage of work, you can start producing current products and their subsequent sale.

As the portfolio expands and authority emerges, large orders will come.

At the initial stage, it makes sense to produce the following types of products:

• Metal bars on windows.
• Wickets.
• Canopies for the porch.
• Fences for various purposes.
• Fireplace accessories.
• Garden gazebos and garden furniture.

Example of financial calculations

Costs for starting a business - 720,000 rubles.

One-time expenses– 635,000 rub.

• State registration – 10,000 rub.
• Organization of work space (repair and equipment of the workshop) – 25,000 rub.
• Purchase of a minimum set of equipment and tools – 400,000 rubles.
• Purchase of the minimum volume of raw materials – 200,000 rubles.

Monthly expenses– 85,000 rub.

• Rent of premises – 15,000 rub.
• Salary fund for employees (2 foremen) – 50,000 rubles.
• Utility costs – 10,000 rub.
• Other expenses - 10,000 rubles.

The average markup is 200% on the cost of production. In a fiercely competitive market, this is the most common markup on cold forging products.

For example: the production of 1 m of lattice for a garden 2 m high costs 535 rubles. (metal – 500 rubles, anti-corrosion paint – 15 rubles, electrodes – 20 rubles). To this amount is added the corresponding share of current expenses (85,000 rubles/250 products per month = 340 rubles).

The planned markup is added to the resulting amount (535+340=875 rubles). As a result, the minimum cost of 1 meter of grating is 2,600 rubles.

Conclusion

Cold forging is more related to the service sector, therefore To determine the profitability of a business, it is necessary to calculate finished products.

It is worth noting that the success of your business will depend on how well you manage it. If an entrepreneur manages to use all production capacities and quickly sell finished products, then the profit from the business will be large and constant.

History of forging.

Since ancient times, blacksmiths have been held in high esteem in Rus'. They were endowed with supernatural power, giving opportunities inaccessible to ordinary people. People often turned to them for help and advice, and during times of illness, a common person often went to a blacksmith rather than a doctor. There was always a lot of trust in them. In the old days, blacksmiths even cemented unions of people. There was a belief that such marriages would be even stronger than church ones. And iron itself in Rus' has long been considered a talisman, and horseshoes to this day adorn many entrances to the house. They are hung to protect against uninvited guests and evil spirits; it is believed that an evil spirit will not be able to pass under the horseshoe. In the old days they believed in the power of a horseshoe attached above the bed. It was believed that it would protect a person’s sleep from nightmarish visions.

Since the times of Kievan Rus there has been no replacement for blacksmiths. From their forges came agricultural implements and craft tools that fed families, household items, weapons and armor for warriors, and harnesses for horses. None of these things can be made with low quality; the life of a person of that time often depended on the skills of a blacksmith, so people who went into this profession were famous for their hard work and attentiveness.

Artistic forging gained momentum in Russia later, in the 17th-18th centuries. This was largely due to the sufficient development of metallurgy. A large amount of metal gave blacksmiths the opportunity to put into practice the experience accumulated over centuries not only to create ordinary things, but also to create mesmerizingly beautiful decorative elements. Around this time, the weight of the blacksmith's products also increased. This became possible thanks to the technological progress of that time. Forges received “samokovs” or, more simply, mechanical hammers driven by water.

What is metal forging? Types of forging.

The definition of forging is given in various regulatory documents of the country as metal forming by local application of load. This strict concept in many ways clearly explains the images of a hammer and an anvil that pop up in the head.
Blacksmithing can be divided into a number of positions. According to the production method, there are manual and mechanical forging. And if the first depends directly on the skills of the master, then the key to success of the second is the presence and coordinated work of all kinds of devices and machines. According to the type of products produced - ordinary and artistic. The degree of heating of the processed metal gives rise to two more types: cold and hot forging. Here we will dwell on them in more detail.
Almost all steel products can be forged either hot or cold. But does this make sense? When cold forging large products, too much effort and time will be spent on this, and when hot forging small products, a significant part of the material will be wasted due to the formation of scale.

Cold forging.

Cold forging is often used instead of stamping or casting, which are much less suitable for creating sufficiently strong parts. This is ensured by simultaneous bending and pressing of the rod during processing. However, forging also has its disadvantages: in the event of a mistake, correcting the mistake on a finished part that is practically not subject to deformation is not always possible in practice and is very labor-intensive. Thus, correcting a defect in one element entails heating the entire product, directly changing the problem area, and then bringing other sections of the structure that were deformed during heating to their original shape.

The scope of application of cold forging products is very wide:
-grills for windows and doors (products can be made according to the standard, or they can be unique works of art created by the hand of a master)
- artistic elements of the facade (lanterns, flower baskets, figured railings of stairs, balconies and much more)
-artistic and simply functional fences, wickets and gates
-decorative furniture and its elements (legs of tables and chairs, benches, etc.)

Automation of the cold forging process and the ability to “cut” products according to a given stencil allows us to produce gratings, stairs, fences and other popular products in fairly large quantities. With this technology, the metal is not heated, with the exception of partial heating of the connecting nodes of the product. The artistic component of this type of metal processing is highlighted by the price issue: the exclusive work of a master costs several times more.

Equipment and tools for cold forging of metal.

Let's look at them in more detail.

This small set of tools is designed to make blacksmithing easier; it is supplemented depending on the goals and capabilities of the master, but it is quite enough to start your own business. Experienced forge masters make many of these devices on their own, the reason for this is the low functionality of industrial designs.

As development progresses, it will be possible to take a closer look at more serious CNC equipment to automate the production of forged products.

In addition to the above equipment, for a successful metal forging business, you also need to stock up on stamps.

Hot metal forging.

Metal forging with preheating is used in cases where, in order to shape large enough products, it is necessary to deform without destroying the material. In a heated state, the metal becomes more plastic and allows various manipulations with it without fear of chips, cracks and other troubles.

The manual labor of a hot forging master is highly valued. This labor-intensive process allows you to create real works of art. Metal roses and lilies, striking in their precise repetition of the lines and sizes of natural flowers. Each product that comes out of the hands of such a master is unique. It will not be possible to repeat the plan twice on hot material: in any case, there will be differences.
Hot forging also has its unpopular features. Firstly, the economic side of the issue: the cost of fuel for forge (chamber) furnaces has not been canceled and this increases the cost of the final product. Secondly, there are difficulties with calculations, because due to the thermal expansion of the metal, the released part is in a hot state more than in a cold state. Consequently, in order for the product to comply with the drawings, it is necessary to make allowance for the compression of the metal during cooling, and for inexperienced craftsmen this is a significant difficulty. When producing products with significant mass, it is also necessary to install additional equipment for transportation, usually mechanical or electric hoists.
The main tools for hot forging of metal include pliers, a sledgehammer, a set of hammers of various shapes and weights, all kinds of punches, crimpers and smoothers, chisels and handbrake tools. Everything that can help give ductile metal the desired shape.

The metal forging business, like many other businesses, begins with a simple hobby. After you have given samples of your products to your friends and acquaintances, word of mouth begins to work and the first clients appear. By this point, you already have experience and some confidence in your “new” job. Confidence helps you communicate with strangers. But don’t forget that you need to constantly improve your skills and experiment.

Your first products will be simple and, in a sense, even primitive, but over time, if you understand that metal forging is truly your business, you will learn to do something that many others will not be able to do. It is also worth adding that each forging master has his own characteristics and his own style in his work, which has been developed for many years and is precisely thanks to which new clients are drawn to him.

You should start your business with minimal investment. If we break down the start of a metal forging business step by step, we will probably get the following picture:

• Education
• Writing a business plan
• Search for premises
• Purchase of forging equipment
• Work as self-promotion
• First clients - first orders
• Main job
• Development – ​​expansion

An important point at the very beginning of a business is studying your region, your future competitors and markets.
You know:

• How many companies and individual entrepreneurs are engaged in metal forging in your region?
• What is the demand for forged products?
• Where do your competitors buy material and at what prices?
• Main markets for products?
• Is this production seasonal?
• What advertising works best in your region?
• What is the average check amount?
• What is the average number of clients over different periods?
• Which forged products are in greatest demand?

In general, the better your research, the more accurate your business plan will be, which will be the key document in your business.
In the business plan, you also need to reflect your uniqueness in your work, which is called indicating your individuality.
If you do not have money to purchase equipment, but after drawing up a business plan you have confidence in your business, try contacting the employment center to receive a subsidy. Many small entrepreneurs manage to receive start-up capital free of charge.

When starting a metal forging business, you should understand that the concepts of cold forging and hot forging are absolutely compatible things. Since both cannot exist without each other. It is impossible to make a stamp on a part without first heating it. There are also parts that need and can be shaped without heating them, which is called cold.

Room. Forging workshop.

Compared to the ancient Russian forge, the modern forging workshop has changed a lot. In the old days, a blacksmith made small items. Routine work included horseshoes or rims for cart wheels and all kinds of household utensils. The pinnacle of creativity of blacksmiths of that time were swords and sabers. Some examples of the work of ancient gunsmiths are still pleasing to the eye in museums today. The production of all this does not require large premises, so the forge of that time was not very large. However, the idea of ​​a blacksmith’s workplace was formed precisely during that period. If the conversation turns to it, our imagination draws us a furnace, an anvil, a hammer and a container filled with water to cool the metal.

Today the forging workshop is a technologically advanced and largely automated production. Sledgehammer blows replaced mechanical hammers. Manual work was given over to programmable machines. The small space expanded to huge areas, divided between assembly, painting, and element creation workshops. The variety of premises varies depending on the type of production. Heating the metal to the deformation temperature was no longer necessary: ​​the hot cutting was replaced by threading using industrial shears.

Large production is unthinkable without significant progressive changes. However, with the increase in the volume of output, its individuality was lost somewhere. The same type of railings and stairs, bars and fences filled everything around. And it was precisely thanks to this that the craft work of the blacksmith began to be revived. Exclusive things have always been in price, and now, when everything around is the same, standing out against the background of monotonous hedges, a hand-forged fence elevates the status of its owner above the rest. Unique forged products are in demand more than ever before. This creates favorable soil for the development of small businesses in the field of artistic metal forging.

To start your own business in metal forging, a room in the form of a garage measuring 6x4 meters, which equals 24 sq.m., will be enough.

The following zones must be located in the room:

Slipway - approximate size 200x200 cm
Desk – 200x80 cm
Procurement zone – 350x40 cm
Rack for metal – 250x50 cm
Ventilation area – 150x100 cm

Process and technology for the production of forged products.

The algorithm for creating a forged product is in most cases very similar. It can be divided into certain stages.

Stage one or what we will actually do. This is the period of searching for drawings, drawings or simply prototypes for a future creation. There are no difficulties with this - fortunately, the Internet and print media have devoted a lot to this issue, and city streets are often full of forged jewelry. Especially talented individuals can independently develop the design of their product.

Stage two – purchase of metal. The standard metal profile has a length of 6 meters. The quantity of material should be planned in such a way that there is no need for a second visit to the supplier or warehouse later. It's better to make some reserve. There are quite a few cases of its application in practice. From a simple error when calculating the material, to accidentally damaged elements during the production process.

After the delivery of metal raw materials, stage number three often arises: pre-processing of raw materials or simply cleaning from rust and dirt. The material could get dirty during transportation, and its surface becomes corroded due to the fact that most metal depots do not bother to build a covered warehouse or even a canopy over rolled metal products.

The fourth stage is already carried out at the blacksmith’s main workplace and involves the manufacture of a frame. For some products it may not be needed, but it is still worth pointing out the features of its production. The frame must have perfectly even corners and match the dimensions. In artistic forging, the frame size is measured along the outer sides.

Stage five. Drawing. Image of the product in a one-to-one scale on a handy surface for subsequent measurements and cutting of metal raw materials. Measuring the length due to the figured shape of the elements is most easily done with a rope: we lay it on top of the drawn line, then, in an unfolded form, apply it to the rod. After this, the required part of the metal is cut off. Everyone understands about maintaining accuracy in all the above-described manipulations.

When assembling products, the production of small elements is always required. The sixth stage will be their creation. Smooth workpieces are given the shape conceived by the master by deformation using the devices described above. If the assembly of the final product requires many similar parts, it is necessary to make them as identical as possible.

By all rules, the seventh stage should imply the collection of all elements into a single creation. Here it is almost never possible to do without adjusting the parts to each other. Trim here, tweak here, the main thing is not to get carried away and not distort the originally intended product. To do this, you need to check the drawing each time. When you are sure that all the parts have been assembled correctly, secure them in place with light welding.

Stage eight. Final welding of all elements together. If it is a lattice or fence, then after boiling all the elements on one side, you need to turn it over and repeat the procedure on the other side. It should be remembered that after the final welding of the elements, it will be impossible to change the type of product. Before you start welding, you should check everything carefully again.

After the product has acquired its almost final appearance, it is necessary to remove all excess. This is the ninth stage. Welding scales do not in any way decorate products for interior or facade decoration, nor do rough welds. The former must be removed, and the latter must be cleaned until the desired smooth shape is formed.

The tenth stage is often associated with decoration products. This is the time to decorate the product. There is a large selection of welding elements available for wrought iron products. When choosing, you should give preference only to options that are similar in style. Different styles of decorating elements can ultimately ruin all the efforts of the master.

The eleventh stage is necessary due to the metal's susceptibility to corrosion. The finished product should be primed and painted. The primer for these purposes should be chosen in an inverse color both in relation to the metal and in relation to the paint. This will make it easier to see flaws in the application. This type of product coating is required for outdoor elements, but if the forged element is located indoors, to save money, you can limit yourself to just a layer of paint.

Stage twelve or how to increase the cost of the finished product. It consists of performing additional activities to decorate the product. Examples include giving the effect of aging or gilding of individual elements. It all depends on the taste of the master or the requirements of the customer, the main thing here is not to overdo it. As they say: the best is the enemy of the good.

Sales of products.

To organize your own good product market, you need to decide on the demographic for which this product is actually suitable and make sure that this potential client wants to buy it here. So for standard products produced by cold forging, such as stairs, railings, gratings, the choice of buyers is very, very wide. However, a business limited only to the production of such products will not always be able to overcome the competition of large factories and industrial associations that have devoted many decades to this issue.

Buyers for artistic forging are more difficult to find, but competition for this item is quite acceptable. Decorative metal products are often needed by people with good or moderate incomes who want to decorate their homes, as well as wealthy offices for decorating office facades. The experience of cooperation with construction teams engaged in the construction of individual houses, cottages, estates or administrative buildings will also be positive. They will take upon themselves the coordination of product sketches with clients, and all you have to do is complete your work on time and with high quality.

It’s good if the work is done to order, but this also needs to be earned. A person usually trusts either something that someone has already tried and given personal positive recommendations, or a well-known brand that will not fail to maintain their own reputation. Any company, even the smallest one, can make its brand popular through advertising. The main thing is not to miss when choosing funds.

The following PR moves are suitable for artistic forging:
- personal contact with the consumer. A face-to-face conversation always gives better results than empty chatter on the phone. The buyer will be more likely to be interested in you if he personally sees your work and is convinced of your professionalism.
- advertising in the media. The cheapest and most expensive type of advertising at the same time. It all depends on the choice of location. The most affordable option is free. This is an advertisement on the Internet on popular sites that have a suitable contingent of visitors. The most expensive is television. The roller will hit your pocket hard at the most opportune time.
- outdoor types of advertising in “suitable” places, for example, a billboard near the entrance to a new cottage community, the construction of which is in full swing.

In any case, you can find a bunch of options both for a well-earning business and for beginners, for whom advertising is a necessary event, but due to the low turnover it is low budget. For industries that have not yet reached full strength, advertising on the Internet or simply submitting an ad in a newspaper is suitable. At the initial stage, you should not shell out money for expensive television or radio commercials; the effect of them is not always immediately visible, and the cost is not always reasonable. Remember, your money should not be wasted.

Costs and profit per unit of production:

This calculation shows that having spent 9,905 rubles on production and sold for 29,700 rubles, you get a pretty good profit.

Investments in metal forging business.

Equipment:

Necessary elements for the production of forged products - 200,000 rubles.
Grinding machine – 2,000 rubles.
Welding machine – 10,000 rubles.
Compressor – 15,000 rub.
Welder's table - 20,000 rubles.
Rack – 10,000 rub.
Slipway – 15,000 rub.
Cutting machine - abrasive - 15,000 rubles.
Ventilation – 15,000 rub.

Total for equipment: RUB 302,000.

Premises:
Rent of premises – 30,000 rubles. per month

Grand total: RUB 412,000.

If the business plan is implemented correctly, the payback period for the business should not exceed 6 months.

Options for manufacturing forged products.