Forged or stock removal Let's dispell the myths

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Sep 13, 2001
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The recent discussion that has sidetracked the CNC thread has prompted me to start this thread. I would like to voice my opinions or the two schools of knifemaking. I use both, so please understand I am not partial to one method over the other so much as I would like to dispell some of the myths that seem to linger over each.

First, we will start with the forging hype. No, forging doesn't improve steel over their inherent abilities they start with. You can get significant grain reduction, but that is a ton of work and I am not sure it is the best method ( you start with large stock and forge at low temperatures to inhibit grain growth as you forge). The top bladesmiths do however tweak their methods and test extensively to ensure they are practicing sound methods.

Anyone can distaly taper a blade. It is a lot less work to forge in a taper with a power hammer than it is to grind it in. That has been my finding. I can forge and grind a blade faster than I can band saw out the profile and gind off the stock. I also HATE to grind that much, so it's a big benefit to my state of mental stability to be able to forge.

Grain alighnment is important, but I don't think the benefit is noticeable in a knife. A forged crankshaft with proper grain alighnment IS better than a billet crankshaft with improper grain flow. That is data from Caterpillar ( I used to work for Cat, and was a failure analist)

Why forge??? Lots of reasons that will differ from smith to smith. I started forging when I was 11. My Father was a blacksmith and farrier, so was my Grandfather and most of my uncles. It's in my blood, and I feel an obligation to perpetuate it. I also like the more intimate interaction with the blade that forging gives me.

Now for stock removal. The problem I see that has plagued stock removal makers is the lack of some intangible method to build hype over. Basicly the stock removal method is too "what you see is what you get" to be able to come up with a marketing plan that allows for "creative" marketing. No "quench in the blood of a red headed virgin by the light of the moon". The Benefit this method does have is the avaiability to use more modern steels and materials. There is simply no need or benefit to forge many of the stainless steels on the market today. In fact, many would suffer under the hammer rather than adding any beneficial prperty. Stainless steels don't move under the hammer easily, require precise and very slow annealing, and are prone to cracking if forged at the wrong temperature range.

I do think an equal blade can be ground out of the same material the forged blade came from. It's just done with a grinder or mill instead of a hammer. For me, on the blades I make by stock removal, it is for the benefits of the modern steels.

As for my grinding method, sharpening methods, edge geometry and so forth....all teh same no matter what the method. I flat grind down to an edge thickness of .010-.015", and roll a convex edge on. I just find it cuts better, is easier for me to maintain, even in the field, and is strong. If a knife is properly heat treated, ground properly to a thin edge ( added benefit of knowing your steels, heat treating them to be hard enough to hold a great edge, and tough enough to support the edge in a thin cross section to provide excellent geometry), and sharpened at proper angles, you shouldn't need to remove metal everytime it needs the edge touched up, and if you do need to remove metal, not too much. I sharpen my knives in the field on the edge of my truck window. One of the benefits of hunting in Texas...your truck is never far away :D . I use a stroping motion, and it works very well.

Obviously this is an open for discussion topic, so if there is a detail you feel is shrouded in mystery or is simply BS, get it off your chest and let's be done with it!!
 
I am very new at knifemaking and have attempted to forge pretty much since i started. There is a certain mystique to it, but the thing I really like is that you are not as limited by the stocxk size, shape, etc in what kind of weird shapes you can make. You can also change your mind up to a point.......raise the point a bit, stretch it out, etc, etc. I know you can do some of these things on a grinder, but with stock removal, once you do something, you are committed..With forging, you can be a bit indecisive:D Also, the heat treating can be a little more simple with forged carbon steels.
 
Thanks for the insight, my feelings all along, heat treatment and edge geometry are the most important. I dislike chisel ground edges and some of the edges some makers put on with a belt sander. A gradual taper to the edge seems better to me, much easier to sharpen. Seems it would also cut better, being less drag. The carbon blades do sharpen easily, but its rough to see rust or pitting on a $800 to $1000 knife. I mean honestly, how many folks are well off enough to take an expensive blade and go hacking in the woods? If I buy a nice forged knife I treat it like a baby and wax it often. I wonder how many people buy expensive blades and when they go fishin or huntin they grab a cheaper blade to use. I know oiling them, and in use ,they develope a patina, but try to ever recoupe an investment in a blade that is not mint, and nobody wants it. I love my knives and guns, but in the back of my mind, I know i can allways recoup my money if things get bad enough. Sorry for rambling.
 
I know you can do some of these things on a grinder, but with stock removal, once you do something, you are committed..With forging, you can be a bit indecisive:D

I don't disagree, but I look at it from the viewpoint of permitting creativity versus accomodating indecisiveness. With forging, you move steel. With grinding, you can only remove steel. Once it's gone, you can't bring it back or put it anywhere else.

To touch upon a point Bailey raised, while it is true that a distal taper can be ground into a stock removal blade, how many stock removal makers actually choose to do so? I am thinking about large blades here - bowies and camps. One of the things I haven't liked about some of the big stock removal blades I have handled is the poor balance and and unwieldly mass that results from carrying a lot of thickness from guard to tip. I'll readily admit that I have far less experience with big stock removal blades and don't for a moment suggest that they are all like this, but who are there makers who consistently grind in a progressive distal taper?

Roger
 
Two schools - who knew!!!
I always thought the handle went on the blunt end and sharp end points away from body. Learn something new everyday.

Great write up, Bailey :D
 
I'll bet that someone is going to state that edge packing is a total myth, and then tell us that Santa Claus and the Easter Bunny don't really exist. Damn you, damn you all to hell.
 
I collect both. If the knife appeals to me and I have the expendable funds, I buy it - stock removal or forged.

I do think as a collector (not a maker) there are some common pros and cons. I use "common" to mean what I see more often than not (and only from my point of view - my cons may be someone else's pros - the nice thing about varying tastes). I'll say this right from the start, when I think forged, I think carbon steel, when I think stock removal, I think stainless - I know its not always so but keep the tomato-throwing to yourself.

Forged Pros:
*Damascus (Ok, there is damasteel, but I don't see it that often)
*That "its made from scratch (kind-of)" sense, the mystique as some call it
*The bluing option (I don't know if this is available in stainless at all - I don't think I have ever seen it)
*HAMON

Forged Cons:
*Rust or the amount of labor to keep it from doing so (yeah, its not that much labor but certainly more than on a stainless and I hate maintenance of any kind - ask my wife how often she has to bug me to dust the stereo system in the living room - the problem is that I won't let her do it :p )
*Many bowies / camp knives / hunters just look the same - I think there is a definite lack of creativeness in a lot of ABS smiths' work (OK, I'll put on my helmet now as I can "see" the stones being picked up ready for throwing) - seriously, a lot of flat ground blades look so similar to me, I don't care what handle material they are dressed-up in. Thank goodness the forged art-knives don't have this same issue.

Stock removal pros:
*Stainless
*Hollow-grind (some of you may bag it, but I really like it, especially from an aesthetic point of view)
*The wider variety of interesting shapes that seem to be made (persians, talons, way-out-there fantasy / art pieces) - these can probably also be done forged, just aren't all that common (even though I own a beautiful forged damascus talon)
*The ability to create some really out-there elaborate artistic shapes

Stock removal cons:
*The amount of trash that is created when you come up with a really funky shape and need to start with a really large piece of steel (some shapes I think of could be done by forging without the trash, but I just don't see them out there much)
*No bluing or hamon

This is just what came of the top of my head. I could likely come up with a few more if I thought more about it.

My present buying habits lean a bit more towards stock removal / stainless, but that is mainly because adding to the maintenance list makes me think twice (usually). :o

That is before I started reading Bailey's post above. Now that I know only forged blades can be quenched "in the blood of a red headed virgin by the light of the moon", I will only buy forged blades :D . (Then again, what if the virgin was blond?)
 
That is before I started reading Bailey's post above. Now that I know only forged blades can be quenched "in the blood of a red headed virgin by the light of the moon", I will only buy forged blades :D . (Then again, what if the virgin was blond?)

That will give you an edge that can't figure out how to be sharp.
 
I forge as it is one of the very few things in life that calm my nerves. The entire forging process is pleasing to me, standing in front of a grinder is not. I love watching, feeling and allowing the blade to shape under the hammer.

Every step of the process in enjoyable for me, I even love to watch the blades come up to heat during normalization...watching the shadows dance and dissapear never ceases to calm me down.

I guess its just the flame/heat that do it for me, and that is very very limited (if existant at all) if a blade is soley stock removed etc.
 
Bailey, I actually came down to Arkansas and did my Intro course with to begin my "Bladesmithing" after doing stock remocal for 7 years. I found it easier to get a blade to shape much faster, and the main reason, was that with even just a little luck, I could forge a blade right here at home and do my own heat treating and be in control of my blade from beginning to end with out sending my stainless blades out to be heat treated, I did not have my own oven at the time, and it was just a heck of a lot cheaper to buy a few gallons of oil that it was to buy a $1000.00 oven!
Anyway, since that time, all of my knives are "Sole Authorship".
(Of course, I ended up getting an oven anyway!)


My "Bible" on forging is Kevin's disertation on his site -

The Lowdown on Smithing -
http://www.cashenblades.com/articles/lowdown/lowdown.html\
 
Forged Cons:
*Many bowies / camp knives / hunters just look the same - I think there is a definite lack of creativeness in a lot of ABS smiths' work (OK, I'll put on my helmet now as I can "see" the stones being picked up ready for throwing)

Got your helmet on yet?:D

I would disagree, if fact take the opposite.

Who many stock removal knives don't resemble a Loveless model?
 
Grain alighnment is important, but I don't think the benefit is noticeable in a knife. A forged crankshaft with proper grain alighnment IS better than a billet crankshaft with improper grain flow. That is data from Caterpillar ( I used to work for Cat, and was a failure analist)

!!



And there IS the superiority.

With equal heat treatment; including proper thermal cycling, there is no superiority other than grain alignment.

And you cant make damascus by stock removal :D

but....

I wonder why high performance engines use forged pistons ?? Hype or proven superior performance.
 
IIRC it has to do with the strength of the material around the pin that holds the piston to the connecting rod, as well as dimensional stability to provide more consistant performance and reliability.
 
And there IS the superiority.

With equal heat treatment; including proper thermal cycling, there is no superiority other than grain alignment.

And you cant make damascus by stock removal :D

but....

I wonder why high performance engines use forged pistons ?? Hype or proven superior performance.

But you can do stock removal on damascus tha'ts already made. :D
 
Matt Lamey hit on another aspect of forging. There are those who LOVE the fire. I do as long as it isn't coal.....well hell I love those too! It does have a raomance to it. I don't know if anything can calm Matt down though....that guy is wound up tighter than the inside of a golf ball :p ( You know I am only jerking your chain Matt)

Forging deffinately offers more freedom in the early stages of the making process, but that freedom is limited to the more simple steels. Rust is an issue, but a minor one with limited care. Still, even being a bladesmith, I like to use more modern steels in my carry knives. My camp/chopper is foged CPM3V ( just cause I can), and my carry folder is S30V.
 
The previous comment about many of the ABS smith's knives looking the same is not without some merit. In my short time as a member, I have noticed that there are "schools" within the group. One can't help but notice how many guys from the South and Southwest make knives that look a whole lot like knives by a couple of chaps from Arkansas whose intitals are JF and JC:D Same thing with some folks from out west who like sheephorn and a fair numer of guys from in and around Maryland who like maple and silver wire. But I must diasagree about the knives being boring. Many of them look similar because that is a design that works. Notice how many folders have lloked like an old Buck or Gerber. I think that some of the stock removal guys mke stuff that is too outrageous looking. Many of thses "art" knives and a fair number of the new tacticals either are, or to my eye, look downright unusable. There is a difference between a knife not being suitable for its intended purpose and an owner not WANTING to use it because it is too valuable. While the ABS may be a bit conservative when it comes to design, that happens to fall right in line with my own opinions, so i am biased:D But you can't argue with success. Read the ABS standards for judging the five JS and MS knives. Implied within those standards is a requirement that the knives must be usable no matter how pretty or strange they look. i know that custom knifemaking has not been just about making tools for a number of years, but I'm not ready for it to become "art for art's sake" just yet.
 
Matt Lamey hit on another aspect of forging. There are those who LOVE the fire. I do as long as it isn't coal.....well hell I love those too! It does have a raomance to it. I don't know if anything can calm Matt down though....that guy is wound up tighter than the inside of a golf ball :p ( You know I am only jerking your chain Matt)

Forging deffinately offers more freedom in the early stages of the making process, but that freedom is limited to the more simple steels. Rust is an issue, but a minor one with limited care. Still, even being a bladesmith, I like to use more modern steels in my carry knives. My camp/chopper is foged CPM3V ( just cause I can), and my carry folder is S30V.
Is S30V easier to sharpen than ATS34? I have had some cool little Benchmade folders and once that factory edge goes both me and my brother have been hard pressed to get it back into that condition. I'mnot sure what they are made of, but my brother has had a simiar experience with his Henckels stainless kitchen knives......even with professiona sharpening, That has never been an issue for me with carbon blades. By the way.....I also hate stainless steel guns and synthetic stocks. Anyone who ends up with rust on their knife or gun only has themselves to blame.
 
Plus it just ain't manly for a knifemaker not to have burn marks and or to still have the same length hair on his non-hammering forearm as on the other one:D
 
But you can do stock removal on damascus tha'ts already made. :D
But you lose the whole potential of the 3-D look from the distortion of the layers when you forge Random and single twist Damascus.
Unless it's maybe a very pattern-specific Damascus that can't be distorted, I think stock removal of Damascus is a friggin' disgrace to the Maker who put his time into making it in the first place.
 
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