English:Producing forged parts by machine forging — Planning and preparation

Introduction

Producing forged parts by machine forging — Planning and preparation is a vocational learning module for blacksmithing, artistic metalwork and related forge work. It focuses on the planning decisions that must be made before hot metal is placed under a power hammer or forging press. You will learn how to interpret a job specification, select material and stock size, choose a suitable machine and tooling route, plan handling and reheating, identify hazards, prepare quality checks and organise the work area.

Selected jurisdiction: England, United Kingdom. Training-pathway information in this module is specific to England. Workplace-safety references are from the Health and Safety Executive and apply in Great Britain, including England. Northern Ireland has a separate safety regulator and is not covered by the legal references in this module. No law, qualification, certification or job title in this module should be treated as automatically equivalent in another country.

Safety rule for this course: machine forging is hazardous. Learners must not operate a power hammer, forging press, forge, furnace or related lifting equipment without competent supervision, workplace authorisation, suitable training and the controls required by the employer's risk assessment, safe system of work and the machine manufacturer's instructions. Official rules, workplace instructions and current manufacturer information take precedence over this learning resource.

Image study: This public-domain symbol shows the traditional hammer-and-anvil relationship. Machine forging uses the same basic idea of plastic deformation by compressive force, but the energy, repeatability and hazard level are much greater.

Course metadata

Field	Course information
Parent course	Producing forged parts by machine forging
Module	Planning and preparation
Target learners	Vocational learners in Blacksmithing, artistic metalwork, craft metalwork and related forge practice
Jurisdiction	England, United Kingdom
Target language	English
Suggested level	Vocational Level 3 orientation, with local delivery adjusted by the training provider
Licence	Course text, original diagrams and original learning activities: Creative Commons Attribution-ShareAlike 4.0. Embedded third-party media remains under the licence or terms stated by its source.
Review status	Ready for expert review against the actual workshop, machine manuals, current risk assessments, safe systems of work and awarding or apprenticeship requirements
Authority check	Current claims reviewed on 1 September 2026 against HSE, Skills England, UK Standards and BSI sources listed below

Learning outcomes

By the end of this module, you should be able to explain the difference between hand forging and machine forging; interpret a drawing, sample or job instruction; choose suitable stock and forging allowances; select machine, dies, tooling and handling equipment; plan a safe process sequence; identify significant hazards and appropriate controls; prepare dimensional and visual quality checks; explain common planning errors; and justify choices using material, quality, safety, cost and sustainability criteria.

Machine Forging in Blacksmithing and Artistic Metalwork

Machine forging in a craft or small-batch forge usually means shaping heated metal with a power hammer or forging press. A power hammer delivers repeated blows. A hydraulic forging press applies controlled squeezing force. Both can draw down, upset, set shoulders, fuller, flatten, texture or form stock when the machine, tooling and workpiece are suitable.

Image study: A blacksmith uses a power hammer in a working smithy. Before the first blow, the operator needs a stable tong hold, clear stock support, suitable dies, a planned sequence and an exclusion zone around the moving and hot work.

Power hammer and forging press: planning differences

Planning question	Power hammer	Hydraulic forging press
How is force applied?	Repeated impacts	Controlled compression
What strongly affects the result?	Blow control, work position, die contact, rhythm and heat	Press force, die geometry, work position, dwell and heat
Typical craft strengths	Fast drawing, tapering, texturing and repeated shaping	Controlled upsetting, squaring, drawing and tooling operations
Key planning concern	Impact, noise, vibration, ejected scale and rapid workpiece movement	Crushing zones, trapped material, hydraulic-system condition and controlled workpiece movement
Operator requirement	Competent, authorised use under the workshop safe system of work	Competent, authorised use under the workshop safe system of work

Image study: This hydraulic forging press illustrates the large forces and restricted working zone typical of pressing. Never infer a safe hand position from a photograph. The actual manufacturer's instructions, guarding and workplace method control the task.

Practitioner terminology

In UK blacksmithing and vocational metalwork, you will commonly hear terms such as stock, billet, heat, drawing down, upsetting, fullering, swaging, flat dies, top tool, bottom tool, set hammer, spring swage, tong hold, scale, reheat, forging allowance, template and gauge. Precise local terminology can vary by forge, so follow the employer's documented terminology where it affects safety or quality.

Planning from the Job Specification

A strong forging plan begins with the required outcome, not with the machine. Read the drawing, model, sample, customer brief or supervisor's instruction and identify the finished dimensions, section changes, bends, shoulders, tapers, textures, holes, interfaces with other parts and required finish. Note any critical dimensions and any surfaces that must remain free of heavy die marks.

A practical planning sequence

Stage	Question to answer	Evidence to prepare
Specification	What must the finished part do and what must it look like?	Drawing, sample, dimensions, tolerances and acceptance criteria
Material	What grade, section and condition are required?	Material identification, stock record or supplier information
Stock allowance	How much material is needed for changes in section and trimming?	Calculation, test piece or proven shop allowance
Process route	Which operations and reheats are needed, and in what order?	Written sequence or route card
Machine and tooling	Which authorised machine, dies and tools suit the geometry?	Machine capacity check and tooling list
Handling	How will the hot work be gripped, supported, turned and transferred?	Tong choice, stock length, supports and team plan
Safety controls	What could cause harm and how will risk be controlled?	Current risk assessment, safe system of work and pre-use checks
Quality control	When and how will dimensions and defects be checked?	Template, gauge, rule, calipers and inspection points

Stock size and forging allowance

Select stock from the specified material grade and section. Allow enough volume for the finished geometry, permitted scale loss, trimming and any test or set-up requirement. Avoid guessing. Use the drawing, a volume calculation, a proven shop method, a sample or a supervised trial piece. For a part that changes from square bar to a long taper, the plan should conserve material rather than simply stretching one end until it looks correct.

A useful principle is that hot forging redistributes metal: it does not create material. When you draw a section longer, its cross-sectional area decreases. When you upset a section, it becomes shorter and thicker. Real workpieces also lose some mass through scale, cutting or trimming, so the planned starting stock must reflect the actual route.

Material identification and heat planning

Low-carbon steel is common in decorative and architectural blacksmithing because it is readily forgeable. Medium- and high-carbon steels, alloy steels, stainless steels and non-ferrous alloys can require different forging ranges, reheating practice and cooling control. You must not rely on colour alone to identify an unknown metal or determine a precise temperature. Confirm the material grade and use the material supplier's data, workplace procedure, calibrated equipment where required and competent supervision.

Image study: Hot steel can remain capable of causing severe burns after visible redness has faded. Planning therefore includes a marked hot-work area, suitable handling tools and a method for identifying hot material to other people.

Tools, Machines and Materials for Preparation

Typical machines and fixed equipment

The exact equipment depends on the forge. A planning list may include the authorised power hammer or forging press, forge or furnace, extraction and ventilation, anvil, swage block, work supports, quench or controlled cooling station where specified, lifting equipment where needed, and guarded grinding or cutting equipment used for stock preparation. Each item must be suitable, inspected and maintained according to workplace arrangements.

Image study: A forging hammer is a substantial machine tool. Planning must include access, floor condition, clear working space, guarding or protective measures, controls, isolation arrangements and the condition of dies and attachments.

Typical hand tools and measuring equipment

Common preparation equipment includes correctly sized tongs, flatters, fullers, set tools, swages, punches, drifts, handled top tools, wire brushes, steel rules, calipers, squares, dividers, radius gauges, templates and go/no-go gauges. Tool condition matters: loose handles, mushroomed struck ends, cracked tooling, damaged tong reins or poorly fitting jaws are reasons to stop and report the defect.

Typical materials and consumables

Common materials include low-carbon steel bar and plate, specified higher-carbon or alloy steels for suitable jobs, sacrificial test stock, marking materials suitable for the process, forge fuel or energy supply, approved lubricants where specified, and finishing materials required by the job. All materials must be identified and stored so that grades are not mixed.

Safety, Law and Workplace Duties in England

This section gives an educational overview, not legal advice. It is deliberately specific to England and Great Britain safety regulation. Official HSE guidance, legislation, the employer's risk assessment, the safe system of work, machine instructions and competent supervision take precedence.

Work equipment and machinery

Under the Provision and Use of Work Equipment Regulations 1998, HSE states that work equipment must be suitable for its intended use, maintained in a safe condition, inspected where necessary, used by people with adequate information, instruction and training, and accompanied by suitable health and safety measures such as guards, protective devices, emergency stops and isolation where appropriate.

For learners, the practical message is simple: do not bypass a guard, interlock, two-hand control, emergency stop or other protective device; do not improvise machine repairs; and do not operate a machine until your training provider or employer has authorised you for that specific equipment and task.

Risk assessment and safe system of work

HSE's risk-assessment approach is to identify hazards, decide who might be harmed and how, evaluate risks, record significant findings where required, and review the assessment. In a forge, the assessment should consider hot metal, crushing and trapping, impact, ejected scale, tooling failure, noise, vibration, heat stress, fumes and dust, manual handling, slips and trips, fire, fuel and gas systems, other people in the work area, and any lifting or transfer operation.

Noise and vibration

Power hammers can create high levels of impact noise. HSE states that the Control of Noise at Work Regulations 2005 use lower and upper daily or weekly exposure action values of 80 dB(A) and 85 dB(A), with an exposure limit value of 87 dB(A) after accounting for hearing protection. These figures are legal exposure criteria, not a substitute for measuring or assessing the actual forge.

HSE also identifies hand-fed forging hammers in its vibration guidance and requires employers to assess and control vibration risks under the Control of Vibration at Work Regulations 2005. Machine condition, tooling, process choice, maintenance and work organisation can all affect exposure.

Heat, fumes, dust and PPE

Hot processes create radiant heat, and HSE advises employers to assess heat-stress risks where work near heat sources may affect workers. Grinding, coatings, lubricants, scale, welding or cutting connected with the job may also produce hazardous substances. COSHH assessment is required where hazardous substances are used or generated, and HSE emphasises preventing or controlling exposure at source rather than relying automatically on PPE.

PPE is selected from the risk assessment after higher-level controls have been considered. HSE's current PPE guidance states that employers must provide required PPE free of charge, ensure it is suitable, maintained and stored, and provide information, instruction and training. In forge work this can include task-appropriate eye or face protection, hearing protection, protective footwear and suitable protective clothing. Glove use must follow the specific risk assessment and machine instructions because PPE must not introduce a new hazard.

Manual handling and lifting

Plan stock length, weight and route before heating. Use mechanical handling or team methods when required by the assessment. HSE guidance under the Manual Handling Operations Regulations 1992 emphasises avoiding hazardous manual handling where reasonably practicable, assessing unavoidable tasks and reducing the risk of injury. If cranes, hoists or other lifting equipment are used, separate lifting requirements may apply and only authorised people should plan and carry out those operations.

Training pathway and occupational standards

For England, Skills England lists the Blacksmith apprenticeship standard ST0378 version 1.1 as approved for delivery at Level 3, with a typical duration of 48 months. The occupational profile covers hot forging and other metalworking processes for small-batch, bespoke and heritage work. This module can support learning within that occupational area, but completing this page does not itself confer a qualification, apprenticeship completion, certification or legal competence.

UK National Occupational Standards also use practitioner terms such as drawing down, upsetting, swaging, punching, forging colours or temperatures, tongs and handling devices, inspection, gauges and templates. NOS are competency references, not automatic licences to operate a machine.

Standards: check scope before applying a document

BSI publishes standards that may be relevant to forged products or machinery, but you must check the scope, edition and contract requirements before applying one. For example, BS EN 10243-1:1999 specifies dimensional tolerances for certain steel drop and vertical press forgings, while BSI states that BS EN ISO 16092-1:2018 concerns presses intended for cold metal and explicitly excludes drop forging from its principal scope. Do not transfer a standard from one machine type, product or country to another without checking applicability.

Risk Controls for Planning and Preparation

Use the hierarchy of controls. Remove or reduce hazards by design before relying on PPE. A typical supervised machine-forging plan considers the following.

Hazard	Planning control examples	Stop-work trigger
Crushing or trapping at dies	Authorised machine, effective guards or protective devices, defined hand-free method, correct tooling and clear safe system of work	Guard or control defect, unclear hand position, unexpected movement
Ejected scale or tooling	Sound dies and tooling, correct seating, controlled work zone, eye or face protection as assessed	Cracked tool, loose die, damaged holder, abnormal vibration
Hot metal	Suitable tongs, stable grip, marked hot zone, planned transfer route, no casual contact	Poor tong fit, blocked route, loss of control
Noise	Exposure assessment, maintenance, noise reduction at source, hearing protection zone where required	Required hearing protection unavailable or control failure
Vibration	Suitable maintained machine, correct process and tooling, exposure control, work organisation	Abnormal vibration or known exposure-control breach
Heat stress	Ventilation, work-rest arrangements, drinking water, shielding and supervision as required	Symptoms of heat illness or failed heat controls
Fume or dust	Eliminate source where possible, LEV or ventilation, suitable process and COSHH controls	Extraction failure or unknown coating on heated stock
Manual handling	Stock support, lifting aid, team plan, clear route	Load exceeds planned handling method
Fire and fuel	Clear combustibles, approved fuel handling, emergency arrangements, correct shutdown method	Leak, uncontrolled flame, missing emergency equipment

Step-by-Step Demonstration: Planning a Supervised Machine-Forged Taper

This demonstration is a planning and instructor-led preparation exercise. It does not authorise independent machine use. The example is a simple low-carbon-steel bar that will be drawn to a specified taper under a power hammer, then checked against a template. The exact stock size, forging temperature, machine settings and PPE must come from the drawing, material data, machine manual and workplace safe system of work.

1. Read the job instruction. Identify finished length, taper length, final section, straightness requirement, acceptable surface condition and any critical feature.
2. Confirm material identity. Match the bar to the material record and reject unidentified or contaminated stock.
3. Calculate and mark the working allowance. Use the drawing, volume reasoning and the shop's proven allowance rather than guessing.
4. Choose the machine route. Confirm that the authorised power hammer and die set are suitable for the stock section and planned operation.
5. Choose the tong hold. Test the tongs on cold stock so that the jaws seat securely and the reins can be controlled without strain.
6. Prepare gauges. Make or select a taper template, rule and square so that checks can be made quickly away from the danger zone.
7. Review hazards and controls. Confirm the current risk assessment, safe system of work, exclusion zone, guards or protective devices, emergency stop, isolation arrangements and required PPE.
8. Carry out pre-use checks. Under supervision, check the machine, dies, tools, work supports, forge or furnace, ventilation and access route according to workplace procedure.
9. Rehearse the movement cold. With the machine isolated where required by the procedure, walk through the route from heating point to hammer, planned work orientation, return for reheat and inspection position.
10. Instructor demonstrates the hot sequence. The competent instructor heats within the specified material range, establishes control of the workpiece, uses light controlled blows first, works progressively along the planned taper and reheats before the steel becomes unsuitable for forging.
11. Inspect away from the dies. Check the taper against the template, verify straightness and look for laps, cracks, heavy die marks, excessive scale or signs of overheating.
12. Record and review. Compare the result with the specification and record what should change in stock allowance, tooling, sequence, number of heats or inspection points before a repeat piece is made.

Process-flow diagram

Specification → Material identity → Stock allowance → Machine and tooling → Risk controls → Cold rehearsal → Supervised forging → Inspection → Record and improve

Common Planning Errors and Corrections

Common error	Why it causes problems	Better planning response
Starting without clear acceptance criteria	The part may look acceptable but fail dimensions or fit	Mark critical dimensions and prepare gauges before heating
Choosing stock by appearance only	Wrong grade or section can forge differently and may be unsafe	Verify material identity and section from records
Using tongs that almost fit	Grip can shift as the section changes	Select or prepare tongs for the actual gripping section
Planning too much work in one heat	The metal may leave its suitable forging range before the operation is complete	Divide the sequence into controlled heats and inspection points
Measuring beside moving dies	Creates exposure to crushing and impact zones	Stop, withdraw and inspect in the designated safe position
Ignoring die condition	Worn or loose dies reduce quality and can create serious hazards	Include die seating and condition in pre-use checks
Copying a machine setting from another job	Different stock, tooling and machines behave differently	Use the approved setting method for the actual machine and job
Treating PPE as the main control	PPE does not remove crushing, trapping, noise or fume at source	Apply the hierarchy of controls and use PPE for residual risk

Quality Criteria

A machine-forged part is assessed against the job specification, not against a vague idea of what looks handmade. Typical criteria include correct material identity; dimensions within specified tolerances; correct length, section, taper, shoulder, radius and angle; straightness or symmetry where required; sufficient but not excessive forging allowance; controlled surface texture; no unacceptable cracks, laps, cold shuts, heavy die damage or overheating; repeatability between parts; correct fit with mating components or templates; and complete job records where traceability is required.

For craft and artistic work, a visible hammer or die texture may be intentional. The quality question is whether that texture is deliberate, consistent with the design and acceptable to the client or specification.

Sustainability and Resource Efficiency

Good planning reduces energy, material waste and rework. Choose near-net stock where appropriate; calculate allowances instead of oversizing every blank; batch compatible heats only when the safe system of work allows it; keep forge doors, insulation and burners in good condition; avoid unnecessary reheating; maintain dies so that parts reach shape efficiently; segregate recyclable steel scrap by workplace procedure; prevent oil and chemical contamination of scrap; and record reject causes so the process can be improved.

Sustainability also includes worker health. A process that saves a few minutes but increases noise, vibration, heat stress or unsafe handling is not a responsible improvement.

Authentic Workshop Examples

1. Architectural ironwork: Plan a repeated gate-bar shoulder under a power hammer so that all bars meet the same set-out line and fit a later assembly.
2. Artistic metalwork: Plan a flowing taper for a sculptural leaf stem, using a template to keep a small series visually related without making them mechanically identical.
3. Toolmaking: Plan the initial drawing of a tool blank while preserving enough material for the eye, striking end or later heat-treatment allowance.
4. Repair and conservation: Plan a replacement forged element from measured evidence while separating historical appearance requirements from modern workshop safety controls.

Media: Observe Machine Forging

The following videos are useful for observation and discussion. They are not substitutes for local training, supervision, machine instructions or risk assessment.

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Observation prompt: Identify the different power hammers, then note which planning decisions would have to be rechecked before moving a job from one hammer to another.

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Observation prompt: Watch how dedicated power-hammer tooling changes material flow. Discuss why tooling design, attachment and machine suitability must be approved before use.

Glossary

Term	Meaning in this module
Billet	A prepared piece of metal stock intended for forging.
Stock	Raw material in bar, plate or other supplied form before forging.
Heat	One cycle in which the workpiece is brought to a suitable forging temperature and worked before reheating.
Drawing down	Reducing cross-section to increase length.
Upsetting	Increasing cross-section by shortening a portion of the workpiece.
Fuller	A tool or die form used to localise deformation and spread material.
Swage	A shaped tool or die used to form or finish a particular section or profile.
Flat dies	Opposing flat working faces used for general drawing, flattening and squaring.
Top tool	A forging tool applied from above, commonly held or guided by an approved method.
Tong hold	The section intentionally left or prepared so that tongs can grip the work securely.
Forging allowance	Extra material or dimensional provision needed to achieve the required finished forging and subsequent operations.
Scale	Oxide that forms on heated metal surfaces.
Lap	A folded surface defect where metal overlaps without soundly joining.
Cold shut	A defect where surfaces meet but do not unite properly during deformation.
Template	A shaped reference used to compare profile, taper, curve or position.
Go/no-go gauge	A checking device that quickly shows whether a feature lies inside permitted limits.
Safe system of work	A documented method that defines how a task is to be carried out with required controls.
Exclusion zone	A controlled area kept clear of people who are not needed for the operation.

Reflection

Consider a forged component you have seen or made. Which feature would be hardest to control under a machine: section, length, taper, symmetry, surface texture or alignment? What evidence would you prepare before heating? Which hazard could be reduced by changing the process rather than adding PPE? How would you know when to stop and seek advice? Finally, identify one planning choice that could improve both quality and sustainability.

Interactive Tasks

Quiz: Test Your Knowledge

What should be established first when planning a machine-forged part? (The job specification and acceptance criteria) (!The loudest machine available) (!The largest stock in the rack) (!The fastest possible cycle)

Why is a cold rehearsal useful before supervised hot forging? (It checks movement, handling and sequence without hot-work pressure) (!It replaces the machine pre-use inspection) (!It proves the material grade) (!It removes the need for supervision)

What is the main material effect of drawing down? (Cross-section decreases while length increases) (!Cross-section increases while length decreases) (!The steel changes automatically to a harder grade) (!The metal loses all surface scale)

Which source should control the permitted operating method for a specific forging machine? (The workplace procedure and manufacturer instructions) (!A social-media clip) (!A setting remembered from another machine) (!A guess based on machine size)

What is a strong reason to prepare a template before forging? (It allows fast comparison with the required profile) (!It guarantees the material grade) (!It replaces all dimensional measurements) (!It makes guarding unnecessary)

Which condition is a stop-work trigger? (A loose die or damaged tool) (!A documented inspection point) (!A clear transfer route) (!A verified material record)

Why should unknown coated stock not be heated without assessment? (Heating may create hazardous fumes or decomposition products) (!Coatings always improve forgeability) (!Unknown coatings prevent scale formation) (!Heating makes all coatings harmless)

What does HSE place before PPE in the hierarchy of controls? (Elimination and engineering controls) (!Decorative finishing) (!Faster production) (!Longer stock)

What does a forging allowance provide for? (Material needed to achieve the specified forged result) (!Permission to ignore the drawing) (!An exemption from inspection) (!A substitute for material identification)

What does completion of this module provide? (Learning evidence that still requires workplace competence and authorisation) (!Automatic power-hammer certification) (!Automatic qualification equivalence worldwide) (!Legal authority to work without supervision)

Memory Game

Drawing down	Reducing section to increase length
Upsetting	Increasing section by shortening the work
Fuller	Tool form that localises material movement
Template	Reference used to compare a required profile
Scale	Oxide formed on the hot metal surface
Tong hold	Prepared section intended for secure gripping

Drag and Drop

Match the correct terms.	Topic
Material identity	Confirm grade before heating
Cold rehearsal	Practise transfer and orientation before hot work
Forging allowance	Provide enough stock for the planned result
Exclusion zone	Keep unnecessary people away from machine forging
Inspection point	Check dimensions and defects away from moving dies

...

Crossword Puzzle

Billet	What prepared piece of stock is intended for forging?
Tongs	What hand tool is commonly used to grip hot work?
Fuller	What tool localises deformation and spreads material?
Scale	What oxide forms on the surface of heated steel?
Guarding	What protective measure helps prevent access to dangerous machine parts?
Template	What shaped reference is used to compare a required profile?

Cloze Text

Complete the text.

A machine-forging plan starts with the . The material grade must be before heating. A calculated helps provide enough stock for the required geometry. The operator prepares suitable for a secure hold. Machine condition and protective devices are checked before . Dimensions are compared with a prepared . Hazards must be controlled using the of controls. Independent machine operation requires workplace as well as competence.

Open-Ended Tasks

Easy

1. Job specification: Highlight the material, dimensions, critical features and acceptance criteria on a teacher-provided forging drawing, then explain which item you would verify first.
2. Tool identification: Photograph or sketch five preparation tools in your training forge and label their purpose without operating any powered equipment.
3. Hazard spotting: From a supervised workshop walk-through or instructor photograph, identify four hazards around a machine-forging station and suggest one control for each.
4. Quality template: Make a safe cardboard or thin-sheet template for a simple taper profile and explain how it would be used away from moving dies.

Standard

1. Process planning: Produce a route card for a simple machine-forged taper, including material check, stock allowance, heats, tooling, handling, inspection points and stop-work triggers.
2. Risk assessment: Compare the hazards of a power hammer and a hydraulic forging press for the same simple part and justify different controls under supervision.
3. Craft interview: Interview a blacksmith, tutor or forge technician about how they plan tong holds, reheats and gauges, then compare the answers with the module.
4. Sustainable forging: Audit a teacher-selected forging process for avoidable reheats, oversize stock, reject causes and idle energy use, then propose two realistic improvements.

Advanced

1. Production planning: Design a supervised small-batch plan for ten matching architectural forged components, including sequence, gauges, traceability, inspection frequency and handling strategy.
2. Tooling review: Evaluate a teacher-provided power-hammer die or press-tooling proposal for material flow, attachment, inspection, access and foreseeable failure modes; do not manufacture or install the tooling.
3. Quality investigation: Examine teacher-provided defective forgings, classify likely laps, cracks, distortion, heavy die marks or overheating evidence, and trace each defect back to a possible planning decision.
4. Expert review video: Create a short instructional video that explains a safe pre-forging planning checklist using an isolated machine or diagrams only, then have a competent instructor review it for accuracy.

Learning Assessment

1. Specification-to-process reasoning: Given a drawing for a tapered bracket, justify the stock section, allowance method, machine route, tooling and inspection points while stating what evidence you still need before production.
2. Hazard-control transfer: Explain how the risk controls would change if the same geometry moved from a power hammer to a hydraulic forging press, distinguishing impact hazards from crushing hazards.
3. Material uncertainty case: A bar is the right size but its grade cannot be verified; explain the correct decision, the quality implications and the safety reasons.
4. Quality troubleshooting: A batch shows variable shoulder positions and heavy die marks; propose a planning-based corrective action that addresses gauges, sequence, tooling and operator feedback.
5. Sustainability decision: Compare two viable process routes for the same component and defend the route that best balances material yield, number of heats, machine time, worker exposure and required quality.
6. Authority and scope: Explain why an apprenticeship standard, an HSE duty and a BSI product standard serve different purposes and why none should be assumed equivalent to a foreign requirement.

Evidence of Learning

Important evidence includes knowledge of machine-forging principles, material behaviour, UK safety duties, quality terminology and the hierarchy of controls; skills in interpreting drawings, calculating or justifying stock allowance, selecting tools, preparing gauges, planning handling, identifying hazards and recording inspection points; products such as route cards, risk-control plans, templates, quality records, annotated diagrams and reflective notes; and transfer achievement shown when you can adapt a plan to a different forging machine, stock section, batch size or quality requirement without transferring unsuitable settings or standards.

Evidence should be reviewed by a competent tutor, workplace supervisor or assessor. Written planning evidence does not replace practical competence, machine-specific training or employer authorisation.

Expert Review Checklist

Before this aiMOOC is used for live workshop instruction, an expert reviewer should confirm that the selected machine types match the local workshop; terminology matches local practice; risk controls align with current risk assessments and safe systems of work; machine manuals and guarding arrangements are current; PPE requirements match the actual residual risks; emergency and isolation procedures are correct; material and quality examples match the course programme; and any qualification mapping is approved by the responsible training provider.

Media and Source Notes

The course text and original learning activities are licensed under CC BY-SA 4.0. Wikimedia Commons items are reused according to their own file-page licences. YouTube videos are embedded as external learning media and are not relicensed by this course.

1. Wikimedia Commons: Blacksmith anvil hammer.svg — public-domain/open-clip-art source.
2. Wikimedia Commons: 4 artist blacksmith forging with power hammer.JPG — Wasapl, CC BY-SA 3.0 and GFDL.
3. Wikimedia Commons: Forging Press.jpg — Supersonic0714, CC BY-SA 3.0 and GFDL.
4. Wikimedia Commons: Blacksmith's hammer on hot metal and anvil — David Whelan, CC0 1.0.
5. Wikimedia Commons: Forging hammer geograph 7576731 — Richard Sutcliffe, CC BY-SA 2.0.
6. Black Bear Forge: A look at my power hammers — practitioner overview; external video.
7. Torbjörn Åhman: Blacksmithing - Forging a power hammer die — practitioner demonstration; external video.

Official References for England and Great Britain

The following sources were checked on 1 September 2026. Always check them again before making legal, training or certification decisions because official requirements can change.

1. HSE: PUWER overview
2. HSE: Risk assessment
3. HSE: Noise at work regulations
4. HSE: Managing vibration at work
5. HSE: Heat stress
6. HSE: COSHH risk assessment
7. HSE: PPE at work
8. HSE: Manual handling at work
9. Skills England: Blacksmith ST0378 version 1.1
10. UK Standards: SEMPEO255
11. BSI: BS EN 10243-1:1999
12. BSI: BS EN ISO 16092-1:2018

Linked Learning Areas

Producing forged parts by machine forging Planning and preparation Blacksmithing Forging Power hammer Forging press Metalworking Occupational safety and health Quality control Sustainable manufacturing