Images of ball tools and products.

All elements from mild steel apart from the ball end punch which is 
from oil quench toughened Progen.

balltools1.jpg

1. Trial run ball. Arrow indicates the remains of the initial 
chamfering of the workpiece prior to going into the ball tools. As it 
did not quite achieve full sphere, subsequent ones had the end 
corners forged in so the bar would go further into the tools.

2. Trial railing stanchion taper and curve, subsequently the ball was 
used to trial the doughnut tools for the cycle barrier project.

3. More doughnut test pieces.

4. Squashed ball for stanchion top, shows nipple on end. The nipple 
can end up the length of the ball diameter on certain tool and work 
piece combinations.

5. Ball end punch. a couple of these in progressive sizes were used 
to rough out the ball tools prior to forging onto the pattern. This 
reduces the amount of drag/relieving and keeps the die shape less 
distorted (sharper/crisper edged hemisphere).

6. 25mm (1") ball tools made for a project 10/15 years ago which had 
25mm (1") balls from  25mm (1") round bar. Tool blocks were hot cut 
from 60 x 30mm (2 3/8" x 1 1/4") by the look of it, I must have been 
keen!

7. 60mm (2 3/8") ball tools. These formed 60mm (2 3/8") balls on the 
end of 50mm (2") bar. Two heats per ball. One heat to chamfer the bar 
end and knock back the corners at 45 degrees. The second forming in 
the ball tools. The workpiece was introduced on flat for the first 
blow and then quarter turns between subsequent blows until the final 
sequence where it was rotated constantly to finalise the shape. It is 
a temptation to introduce the workpiece on the arras for the first 
blow but this will result in folds and flashing which will screw up 
the ball.



balltools2.jpg

shows closer up tools to see edge softening / relieving proportion. 
Also ball end punch semi profile.


balltools3.jpg

Closest up tools. I tend to lubricate tools like this with flake 
graphite  and have found it easiest to apply between heats when mixed 
with wax.


balltools4.jpg railing stanchion project

balltools5.jpg bicycle barrier project