Some of the different varieties of forging processes are impression die forging, cold forging, and open die forging.
FREMONT, CA: To shape metal parts, four types of forging manufacturing processes are commonly used. The forging processes include impression die forging (closed die), open die forging, and seamless rolled rings. Metal forgings create a wide range of parts for all applications using localized compressive forces.
Impression Die Forging: The impression die forging process, sometimes called closed die forging, uses dies that completely enclose the base material, making it easier to shape it. Impression closed die forging requires greater compressive forces than other forging processes to ensure the die cavities are filled, and the part is formed completely.
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There are many types of 3-D parts made by impression die forging, ranging from a few ounces to several tons.
The advantages of Impression Die Forging include the following:
• Reduces the amount of metal waste generated
• A higher rate of production.
• Enhances fatigue and impact resistance
• Enhances the strength-to-weight ratio of parts.
Open Die Forging: Known as smith forging, open die manufacturing uses direct force to shape parts. In open die forging, the workpiece is struck and deformed by a hammer. Due to the fact that the dies do not enclose the workpiece, this process is called open die forging. This forging process uses dies more like tools than enclosed molds.
The open die forging process is ideal for parts weighing over 200,000 pounds and can produce forgings weighing as little as a few pounds to more than 150 tons. The length is 80 feet.
The advantages of open die forging are:
• Fatigue resistance has been improved
• The flow of continuous grain
• Parts with a longer lifespan
• Strengthening
• Voids are less likely to occur
• Grain size that is finer
Cold Forging: Cold forging produces parts and components with improved surface finish and tight tolerance dimensions. The cold forging process, unlike most other forging processes, uses colder temperatures to shape part structures.
Parts and components created by cold forging include shafts, hollow parts with shafts and stems, odd configurations, and cup-shaped geometries.
The advantages of cold forging are:
• Tolerances are tightened
• Provides a good surface finish
• Affordability.
• There is little to no material waste
• Heat forging dies last longer than dies used for die casting
• Tensile strength and yield strength increased
The options for cold forging materials are:
• Gold
• Silver
• The copper element
• The brass
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