Parts and components created by cold forging are characterized by excellent surface finish and tight tolerance dimensions. A cold forging process produces various components without using heat to shape the part structure, unlike most other forging processes.
Fremont, CA: Metal parts are typically shaped using four types of forging manufacturing processes. A seamless rolled ring is forged through impression die forging (closed die), cold forging, open die forging, or open die forging. As a result of using localized compressive forces, metal forgings offer a highly effective method for creating a wide variety of parts.
Impression Die Forging
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In impression die forging, dies to enclose the base material completely, allowing the material to be shaped into the desired shape more easily. Impressions closed die forging requires greater compression forces to ensure the die cavities are filled, and the part is formed.
A few ounces to several tons of 3-D parts can be created using impression die forging processes.
Impression Die Forging Advantages
- Reduce metal waste generation
- Productivity increases
- Enhances fatigue resistance and impact resistance
- Strengthens and lightens parts
Cold Forging
Parts and components created by cold forging are characterized by excellent surface finish and tight tolerance dimensions. A cold forging process produces various components without using heat to shape the part structure, unlike most other forging processes.
It is used to create shafts, hollow parts with stems and shafts, odd configurations, and cup-shaped geometries, among other parts.
Cold Forging Advantages
- Maintains tight tolerances
- Produces a high-quality surface finish
- Cost-effective
- Material waste is minimal to nonexistent
- A heat forging die lasts longer than a cold forging die
- Strengthening and increasing the yield of the material
Cold Forging Material Options
- A gold coin
- An emerald
- Stainless steel
- The metal brass
Open Die Forging
Open die manufacturing is also known as smith forging. During open die forging, a hammer strikes the work piece and deforms it. Due to the fact that the dies do not enclose the work piece, this process is known as open die forging. The dies are used more as tools than as enclosed molds in this forging process.
An open die forging can produce forgings that weigh over 200,000 pounds and can be as heavy as 150 tons. The length of the boat is 80 feet.
Open Die Forging Advantages
- Resistance to fatigue has been improved
- Grain flow that is continuous
- A longer life expectancy for parts
- Strengthened
- It is less likely that voids will occur
- The size of the grain is finer
Seamless Rolled Ring Forging
In seamless rolled ring forging processes, a hole is punched in a thick, round piece of metal, followed by rolling and squeezing to form a thin ring. In contrast to other forging processes, rolled ring forging uses curved dies instead of flat ones to form ring-shaped components.
There are many advantages to seamless rolled ring forging
- The integrity of structure is superior
- Strengthened
- Directional control
- Porosity, welding, and inclusions are eliminated
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