There are a number of options to choose from when it comes shaping or creating a metal part. This includes investment casting, open die forging, centrifugal casting, rolled ring forging, sand casting, heat-resistant casting, and closed die forging, among others. Amongst all these forging techniques and methods, one of the most commonly used methods is closed die forging.
With a variety of available options, one must be proficient in understanding the metalwork technique they require. The same applies for closed die forging as it must be chosen after gaining a thorough understanding of its importance, usage, and the various advantages it offers. Let’s start off by understanding the closed die forging process.
Closed Die Forging
This popular forging method is sometimes also called as an impression die forging. Its process involves the inclusion of two or more dies, which comprises a precut profile of the required component. Following this, the heated raw material or component is positioned to be placed at the bottom of the die. The dies are then seen to be moving towards each other. This continues until the raw material is produced or formed into the requisite shape and size.
In a closed die forging process, almost all metals and alloys can be forged. Materials like aluminum, stainless steel, titanium, steel, and various other alloys can be used to produce a wide pool of 3-D shapes in a variety of sizes and weights, accordingly. This is one of the primal reasons behind its popularity as closed die forging is considered to be one of the best processes to produce complex shapes which need or require elaborate or detailed design elements. The process has numerous applications across different industries, most notably in the construction, defense, engineering, aerospace, power generation, oil and gas, and other industries. It offers unmatched strength and toughness to the manufactured products and boasts various advantages to its name.
- Net or Accurate Shapes – Closed die forging has an uncanny ability to create net or almost accurate shapes. This invariably helps save a lot of time and money spent, one which would be otherwise required for additional machine work.
- High Strength and Durability – When compared to casting, the closed die forging tends to show superior or a higher level of mechanical properties. This is mostly because of the formation of internal grain structure that is followed by a part’s general shape. The grain flow internally further leads to a higher strength and durability of the product. This means that the process has a wider scope of applications as compared to others owing to its better working performance level.
- Close Tolerances – As mentioned previously, the closed die forging process gives one a near net or accurate shape, this thereby means that clear tolerances can be attained through the same. To be fair, for some of the small products, a tolerance of close to +/- 0.3mm can be achieved. Furthermore, this requires little to no machining, thereby saving on the costs part.
- No Limitation on Materials – Irrespective of whether it is brass, aluminum, or steel, all such materials can be used for this process of forging. It is also extremely suitable for various other metal alloys as well.
- Smoother and Better Surface Finish – Unlike the casting process, the closed die forging technique provides a far better surface finish, especially because of its precise shaping characteristics. This factor too saves upon the cost of machining.
As proven above, the closed die forging process has a wide number of advantages to its name. Now, it is time for you to choose the same after ascertaining your own set of requirements.