Advantages of Forging

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Sometimes referred to as near-net-shape or impression die forging, closed die drop forging offers numerous technical advantages

Drop forging saves on material usage and carries an upfront tooling investment that&#;s not nearly as expensive as you may think.

Drop forgings are available in a wide range of ferrous and non-ferrous materials ranging from standard carbon & alloys steels, duplex, super duplex, nickel superalloys, and other non-ferrous alloys. Size ranges from as little as a few grams up to many tonnes.

Grain Flow Structure Example

Improved Strength to Weight Ratio

In the closed die drop forging process, a metal bar or billet is heated before being placed in the die then hammered until the metal completely fills the die cavity. During this process of plastic deformation, the material&#;s grain structure becomes compressed and aligned to the component shape which imparts greatly increased directional ­­strength with reduced stress concentrations in corners and fillets. Components manufactured this way are stronger than their equivalent machined-from-solid or cast parts.

Structural Integrity

Forging a component greatly reduces the possibility of metallurgical defects such as porosity or alloy segregation as found in some castings. This leads to reduced scrap, a uniform response to heat treatment, and predictable component performance in the field.

There is virtually no possibility of porosity being introduced during the forging process. Even this can be checked with a low-cost ultrasonic test after manufacture. The possibility of small surface cracks can be managed with a simple crack detection procedure towards the end of the process.

Post Forging Machining

Parts can be machined post forging with no loss of quality because there are no voids or porosity in the fished article. Forging is often combined with machining for improved dimensional accuracy. This can also be achieved by post forge coining or sizing.

Cost Benefits

Moving from machined-from-solid to forged components generates a saving in raw material usage. Starting from a near-net-shape forging can also reduce machining times. This means companies moving from machine-from-solid to machine-from-forging can generate enough capacity on their existing plant to save capital outlay on new machinery, as their business grows.

Customers often assume that the initial tool cost required for near net shape forging is prohibitive. In fact, forging dies and tools are quite simple in construction and are relatively low cost, making them viable even for jobs with low production quantities. This cost can be further mitigated by amortisation into the component piece price and even reclaiming pre-used die materials.

Die Life

Closed die forging tools typically last between and cycles in more common carbon materials but can be as low as 100 cycles where very complex shapes are required in high-strength super-alloys. Die life expectancies are greatly reduced by sharp corners, material forge-ability, and very close tolerances. Some of these limitations can be offset by incorporating multiple impressions into the die design or by pre-forming the metal billet before putting it into the dies.

Cycle Times

Forging cycle times are rapid: a typical forging is often complete within 10-30 seconds. However, some complex shapes require complex procedures where the level of skill and experience of the Stamper plays a key part.

Design Opportunities

This process is suitable for low-volume production as well as one-offs. This is because it produces parts with superior strength-to-weight properties that cannot be manufactured in any other way. Small volumes can be machined from solid, but they will have to compensate for reduced strength brought about by random grain alignment.

For more information, please visit Precision copper forging parts Supplier.

Undercuts are not possible in forging, however, it is possible to form undercuts and form joints with secondary forging operations. These processes can be used to make a huge range of component sizes and geometries.

Design Considerations

Designing for forging must take into account a number of factors including partition line, draft angles, ribs, radii, and fillets. Parts are formed by hammering, or pressing, which can produce surprisingly deep protrusions, up to 6 times the thickness of the material. Draft angles can be minimised and even eliminated by clever design, especially in ductile materials like aluminium (aluminum) and brass. Radii, however, are very important because they encourage the flow of metal and reduce tool wear. The minimum radius increases with the depth of protrusion.

Compatible Materials

Most ferrous metals can be forged, including carbon, alloy, superalloy, and stainless steel. Non-ferrous metals including aluminium (aluminum), brass, copper, and titanium are also suitable.

Environmental Impacts

A Forge is a relatively dangerous process to work and health and safety are maintained by operator training, controlled production procedures, and involvement of the workforce.

Noise and vibration can be managed with up-to-date damping under the hammer unit and the correct building structure.

The forging process provides optimum use of materials with little waste. All trimmed flash and offcuts are recycled and of course, all-metal components can be recycled at the end of their life-cycle.

Closed Die Forging: Advantages and Disadvantages in Modern Manufacturing

Closed die forging, otherwise known as impression-die forging, is a process used mostly for manufacturing small scale precision parts. The process compresses two closed dies together, both with a mould or impression inside, until the two billets meet, leaving the piece of metal inside to form a particular shape inside the parts. This method of forging manufactures higher quality products with an increase in strength and durability. So what are some of the other advantages and disadvantages of this process?

Advantages:

In closed die forging, the metal is manufactured by pushing the grain together. This in turn means the internal structure is compressed and reinforced, producing a continual grain bond throughout the solid shape. This, of course, leads to higher strength and improved working performance.

The benefit of closed die forging is that similar to CNC machining, there are much better accuracy and net shape results than open die forging, due to the two moulds being pushed together forcing the metal to form a more precise shape.

Due to the fact that closed die forging relies on durable and reinforced methods of shaping and manipulating, the process is suitable for almost all types of metal, so long as the metal being shaped is heated to an appropriate temperature.

Another advantage is the use of a closed die method forces the metal to form a precise shape and causes a strong surface finish. As the moulds and surfaces in which the metal is pushed between are smooth, the finish is very similar to CNC machining in Australia and much less rough than open die forging. This of course means fewer post-production costs, leaving the price per unit less and allowing for a higher quality product to be produced for less.

As the precision in closed-die forging is much more reliable than open-die, it can often minimise the need for post-machining. This can be a more cost-effective way of achieving a certain shape when producing multiple copies of the same design. As the method is also enclosed and confined within the moulds, less clean-up is required, less waste is produced and the time it takes to prepare between operational production is lessened. This can also be considered a more environmentally friendly method of producing as the risk of waste and tiny shards of metal are eradicated.

While close die is perfect for mass production for smaller-scale objects, there are still some definite disadvantages.

Obviously, due to the limits of the forging press and the components it takes to forge, there are certain size limitations to consider when thinking of producing with the closed die process. There are also shape limitations to consider, those with an irregular shape, or shapes that aren&#;t mirrored on each side, also those with internal parts or details within the shape, as the metal will only fit around the crevices made, there is a low level of allowance for specifications inside a particular shape.

Another disadvantage is that initial tooling costs for producing the moulds are high, making the method not cost-effective when conducting short production runs or runs with a wide variety of sizes and designs.

Our team specialises in forging and has done for many years due to the reliability and durability that it maintains years after it is manufactured. We have worked closely with many industries, including aerospace, automobile, agriculture, oil, mining, and railroad. At Greg Sewell Forgings we offer closed die forging that match or exceed each industry&#;s specifications and expectations, including special certifications. We work closely with our customers in each industry to create incredible products that result in high durability and extended life.

To enquire today about your specifications or chat to us for some advice, call us on +61 3 .

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