When it comes to the forging process, there are many different types. One of the more popular types used to create parts that are used in your everyday life is through open die forging.
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The open die forging process is a popular and effective way to produce the parts that you need and use on a daily basis. The process itself consists of deforming metal parts by heating them between a top die attached to a ram and bottom die. Depending on what type of metal is used, it will be exposed to temperatures that range between 500 °F to °F while slowly shaping the metal into the desired shape. This is done through pressing and/or hammering the metal into place. The process usually requires a secondary machine or refining in order to reach the desired specifications.
Even though parts created through open die forging usually require secondary machining, it is still a popular process that sees results. Parts created by open die forging are:
The biggest benefit of this type of forging is that the repeated working of the metal increases its strength and grain structure of the finished product. Parts made by this type of forging are tough and last long. They are resistant to fatigue and typically have a lower number of voids compared to other processes.
Finding the right forging method for your metals requires knowing your options. Here is the complete guide on open die forging vs. closed die forging.
As of , the global metal market is worth around $3,949 billion. This makes sense considering the number of applications metal has in our daily lives. Metal is a staple of our existence, from movable bridges to aluminum space equipment to consumer electronics.
Open die vs. closed die forging are two metal forming options for those who want to have custom metal parts manufactured. Here, we will discuss these two metal forming processes and how they impact grain flow and utility. Read on to learn which approach best meets your needs.
Open die forging is a metal forming process that uses multiple dies. None of these dies completely enclose the material as the component is being shaped. Instead, the dies hammer the metal over and over until the forger creates the desired end shape.
Before the process begins, the metal is heated in a furnace. This makes it malleable so that dies can alter its shape.
Hammering and pressing the metal lets you achieve any shape. Assuming that the expert making the material understands metalworking, they will know exactly how to change the billet's dimensions without needing to fully enclose the metal. Open dies are simpler than closed dies because they do not require a specific shape to contain and shape the metal.
The grain flow structure is one of the most significant open die forging benefits. As the metal is worked into the desired shape, grain flow is strengthened as it follows the contour of the piece. The grain flow movement is possible because force is applied to the metal during various forging operations, including upsetting, drawing out and/or rolling.
These methods of forging create a final product that is not porous. In fact, the final product will be stronger and more durable due to its even grain flow and improved microstructure.
Some other open die forging benefits include:
Continuous grain flow and finer grain size
Consolidation of voids in the material
Greater fatigue resistance for long-term use
Eliminates shrinkage and similar defects
Less material waste (eco-friendly)
Better production scheduling as different parts can run through the shop at the same time
There are also a few disadvantages:
Usually requires some machining to create the correct dimensions
The inability to create shapes with intricate inner passages
Rough surface finish (unless refined later)
Open die forging is the most conventional metal forging process available. As a result, despite its shortcomings, it is ideal for R&D, prototypes, oversized components or small-run applications.
Closed die forging is a slightly different process than open die alternatives. It is not a free forging process. Instead, it is often called "impression die forging" because it uses a die impression to give the metal its shape.
Like open die forging, the metal for closed die is heated in a medium frequency induction heating furnace. However, it is then placed in an enclosed die molded in the desired shape of the final product. Then, the metal is compressed and formed into the end product through high pressure or multiple hammer impacts.
Molding dies are made with precision machines before a metal preform is placed between the top and bottom dies. Depending on the component type, machining might not be needed after the end product is removed from the die. This is because the closed die process creates intricate components depending on the detail of the dies.
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Like open die forging, internal grain flow is formed since material reduction is involved in creating the product.
There are some things closed die forging excels at:
A cost-efficiencies are realized with this method for large production runs
Little machining is required in most cases (for close tolerances)
The ability to create tighter tolerances
Still, other areas are lacking compared to open die forging. These downsides include:
High costs are associated with the manufacturing of the dies making this process too expensive for short production runs (since the die production costs are high)
The time to produce the dies can push out your deadline
Constrained capacity in closed die shops (Once a run is booked, they are locked into that one part until production is complete)
Ultimately, certain applications require closed die forging methods. However, it is less conventional than open die methods.
Open die forging is generally used for products manufactured in small quantities, require large sizes, and are critical for the end user or R&D. Generally, open die forging shapes are easy and used for more straightforward shaped products (rather than complex ones).
Some examples of products made from open die forging include:
Small discs
Forged and rolled rings
Forged cylinders
Domes
Rollers
Forged shafts
Metal sleeves
These products are often used in shipbuilding, mining, defense and energy industries. However, they are also used in the machines that manufacture semiconductors, food/beverage equipment, industrial machinery, paper and more. Furthermore, with a skilled Forge Development team, like the one at Scot Forge, many complex shapes can be manufactured through the open die forging methods.
On the flip side, the closed-die forging process is generally reserved for creating smaller and more complex products and large production runs.
Forged fittings
Lifting hardware
Rigging hardware
Small/precise car parts
Valves
Because of the precision level, closed die forging is essential in industries like commercial aircraft and automotive markets. In general, forgings keep users safe from part malfunction due to the contoured grain flow resulting in higher strength components.
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