Block forging can be broken down into two different types: open die block forging and closed die block forging. This type of forging is frequently called drop forging because the metal block is shaped by raising and then dropping a hammer onto the heated block of metal to shape it. Block forging is a process commonly used within a forged components manufacturer.
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The oldest and most prominent type of block forging is known as open-die drop forging or smith forging. Basically, this is where a block of steel is super-heated and then hammered on a stationary anvil. The reason this type of forging is called open-die is because the surfaces that touch the block being worked do not completely surround it as it is being worked. This allows the block shape to flow into the areas that are not touching the sides of the die. For this reason, the person performing the forging process needs to reposition the block frequently so the that the block is hammered into the desired shape. The dies used for most open die block forgings are flat, although some dies are rounded or curved, and still other shapes may be used for specific situations.
The open die block forging can shape blocks of metal into many different shapes. These shapes include discs, cylinders, hex-shapes, flat shapes, and many others. The type of shapes that can be made are limited only by the shape of the open die used for the forging process. Open die forging also can be used to prepare the metal for future work by molding it into the rough shape needed for future forging processes. Open die forging also is used to increase the strength of the metal by orienting the grain properly.
Closed die block forging, also known as impression die forging. Places a block of metal into a mold-like metal die which completely surrounds the block. This die is attached to an anvil and then the hot metal is hammered in quick, repeated strikes, causing the metal flow into the die and assume the shape of it. Once you have the desired shape, most blocks will be reworked into other similar (and possibly more complex) shapes, to fine-tune the design. A block subjected to closed die block forging may undergo this treatment several times before it reaches its final shape&#;with each die shape being a bit more complex than the previous shape.
FCI offers in-house forging, heat treating, machining and NDE services. Our facilities are equipped with 350-ton, 1,750 ton, 2,000- and 3,000-ton open die hydraulic forge presses and a 14,000-pound hammer. FCI manufactures primarily open die forgings of any shape weighing from 5 to 55,000 pounds. Forged Components is the premier provider of large diameter industrial forged flanges and ASME pressure vessel connections for the oil & gas, and petrochemical industries. For more information, call us at (281) 441- or contact us online to get a quote today.
Block forging can be broken down into two different types: open die block forging and closed die block forging. This type of forging is frequently called drop forging because the metal block is shaped by raising and then dropping a hammer onto the heated block of metal to shape it. Block forging is a process commonly used within a forged components manufacturer.
The oldest and most prominent type of block forging is known as open-die drop forging or smith forging. Basically, this is where a block of steel is super-heated and then hammered on a stationary anvil. The reason this type of forging is called open-die is because the surfaces that touch the block being worked do not completely surround it as it is being worked. This allows the block shape to flow into the areas that are not touching the sides of the die. For this reason, the person performing the forging process needs to reposition the block frequently so the that the block is hammered into the desired shape. The dies used for most open die block forgings are flat, although some dies are rounded or curved, and still other shapes may be used for specific situations.
The open die block forging can shape blocks of metal into many different shapes. These shapes include discs, cylinders, hex-shapes, flat shapes, and many others. The type of shapes that can be made are limited only by the shape of the open die used for the forging process. Open die forging also can be used to prepare the metal for future work by molding it into the rough shape needed for future forging processes. Open die forging also is used to increase the strength of the metal by orienting the grain properly.
Closed die block forging, also known as impression die forging. Places a block of metal into a mold-like metal die which completely surrounds the block. This die is attached to an anvil and then the hot metal is hammered in quick, repeated strikes, causing the metal flow into the die and assume the shape of it. Once you have the desired shape, most blocks will be reworked into other similar (and possibly more complex) shapes, to fine-tune the design. A block subjected to closed die block forging may undergo this treatment several times before it reaches its final shape&#;with each die shape being a bit more complex than the previous shape.
FCI offers in-house forging, heat treating, machining and NDE services. Our facilities are equipped with 350-ton, 1,750 ton, 2,000- and 3,000-ton open die hydraulic forge presses and a 14,000-pound hammer. FCI manufactures primarily open die forgings of any shape weighing from 5 to 55,000 pounds. Forged Components is the premier provider of large diameter industrial forged flanges and ASME pressure vessel connections for the oil & gas, and petrochemical industries. For more information, call us at (281) 441- or contact us online to get a quote today.
Forging is one of the oldest forms of metalworking. It produces parts and components that are stronger than those that are machined or cast. As metal is shaped during the forging process, its internal grain structure deforms to follow the general shape of the part or component.
As a result, the grain structure is continuous throughout the part or component, leading to superior strength characteristics, such as reliability at high stress points. As such, OEMs rely on forged products for critical "cannot fail" parts and components being used in airplanes, tractors, ships, automobiles, drilling and mining equipment, etc. These forged products also have to work well while in motion, such as gear components.
This metal forming can be accomplished by either "hot forging" or "cold forging" processes, both of which have multiple sub-categories. One of the most common processes is a type of hot forging known as impression die forging (also known as closed die forging), which is the process utilized by Rex Forge. This method uses powerful presses and/or hammers and relies on the shape of the dies, which are essentially cast impressions of the end product. The five steps of impression die forging are:
Pre-forged metal starts with metal blocks called "ingots," which come in a variety of shapes and sizes depending on the part or component to be produced. These ingots are heated to a near molten state where the metal still retains its shape but can be altered easily with force.
In order to form a piece of the ingot to be pressed between the closed dies, the heated ingot is edged and blocked with a press or hammer. Edging is done to increase the working cross section and blocking is implemented to refine the shape for finish forging.
To complete the shape, the preformed metal is forced into an impression between two dies; this is where the metal takes on the general shape of the end product. Simple items may only need one press, but more complicated items may require multiple strokes at different pressures or even different dies to design the final product.
By coordinating the cooling of the metal, forgers can increase the strength of the final product by deforming and optimizing the grain flow within the metal. A unique aspect of impression die forging is the "flash," which is the excess metal that flows outside of the dies. The flash cools and hardens rapidly causing it to be stronger than the metal in the dies. This forces the metal in the dies to completely fill any cavities.
Once a forged product has gone through the pressing process, trimming and other surface treatment operations are performed in order to improve the dimensional accuracy of the forged product. Surface treatment can be completed to enhance corrosion resistance and improve the appearance of the finished forged product.
However, the benefit is a low recurring cost for each forged part or component produced, thus becoming increasingly economical with volume. And, impression die forgings generally have about a 20% higher strength-to-weight ratio when compared to machined or cast parts of the same material. These characteristics make impression die forgings popular with automotive and tooling industries.
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The two main types of presses are mechanical and hydraulic. Mechanical presses function by transforming the rotational force of a motor into a transitional force that preforms the pressing action. One advantage is that different forces are available at different stroke positions. Another advantage is that mechanical presses are faster than hydraulic ones. Hydraulic presses use fluid pressure and a piston to generate force. The advantages of a hydraulic press over a mechanical press are its flexibility and greater capacity. The disadvantages include a slower, larger, and costlier press to operate. Rex Forge uses mechanical presses due to the type and volume of forgings required by its customer base.
Other forging processes include drop forging (a form of open die forging), in which a piece of either hot or cold metal is repeatedly struck and deformed by a hammer to form a shape; and seamless rolled ring forging, in which a round ingot can be formed and manipulated to form rings of almost any diameter and thickness.
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The Different Types of Forging Processes
Four types of forging manufacturing processes are commonly used to shape metal parts. These metal forging processes include impression die forging (closed die), open die forging, cold forging, and seamless rolled ring forging. Using localized compressive forces, metal forgings provide a highly effective way to create various parts for all applications.
Great Lakes Forge is a proud provider of open die forging services and other types of forging operations. Contact us today for more information about open die forging and learn what we can do for you.
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Often referred to as closed die forging, the impression die forging process utilizes dies that completely enclose the base material, making it easier to shape the material into its desired shape. Compared to other types of forging operations, impression die forging requires greater compressive forces to ensure the die cavities are filled and form the complete part.
The cold forging process is designed to create parts and components that display enhanced surface finish quality and tight tolerance dimensions. Unlike most other types of forging, cold forging does not utilize heat for part structure shaping but rather colder temperatures to produce various components.
Cold forging is used to create various parts and components, including shafts, hollow parts with shafts and stems, odd configurations, and cup-shaped geometries.
Custom Forged Parts
Also referred to as hammersmith forging, open die manufactured parts are shaped through direct force. A hammer strikes and deforms the workpiece, held in place by two flat dies. This process is called open die forging because the dies do not enclose the workpiece. Within this metal forging process, the dies act more like tools rather than enclosed molds.
Open die forging can produce forgings from a few pounds up to more than 150 tons and is ideal for parts weighing over 200,000 lbs. and 80 feet long.
Open Die Forging
Typically performed by punching a hole in a thick, round piece of metal and then rolling and squeezing the donut into a thin ring, seamless rolled ring forging processes are ideal for producing ring diameters ranging from a few inches to 30 feet. Compared to other types of forging, rolled ring forging utilizes curved dies instead of flat dies to form ring-shaped components.
Great Lakes Forge is your trusted provider of open die forging services for metal part manufacturing. Contact us for more information on our custom forging service options, or call us at 800-748-, and we&#;ll help you find the best custom forging solutions for your project.
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