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Guidelines for Buyers to Order Closed Die Forgings

It has been a long history since closed die forging is worked as the metal forming process. Closed die forging is now a major global manufacturing industry and supplys metal components to many industries: automotive, defense, aerespace, agriculture, oilfied and others. Since closed die forging is a manufacturing methods for metal components, it is imperative for buyers to understand some related information about it. 

Forging Type


Unlike casting, closed die forging is the process that shaping metals into desired dimensions in a solid state. Compared with other forging types( Open die forging, ring forging, ect), closed die forging is the most common process. This is the shaping of hot metal completely within the walls or cavities of two dies, that come together to enclose the work piece on all sides. The impression for the forged design can be entirely in either die, or split between the top and bottom dies.

Process Flow of Closed Die Forging



To have a better understanding of the process flow, let’s break it down into steps. Before starting of closed die forging process, the forging manufacturer must source the raw material from either steel factory. Once this relationship is built, the forging company will arrange to store raw steel bar into material warehouse that should ultimately meet the quality specifications required by the end customer, meanwhile the material certification should be supplied by material factory. According to the dimensions of products, the bar stock is then cut or stamped to the proper length, based on the part requirements, and sent to the processing area.

Now that the material is in billet form, it is heated by medium frequency furnace, then placed on the bottom half of the die either manually by an operator or by an automated process. Next, the forging press stamps the billet into the cavity of the dies.  Now, remove the newly forged part from the die and placed it in a separate storage area for cooling under room temperature. Then stamp the forging blank again under trimming dies to remove the flash around the shape. After that, we will see some scale cinder left behind, which is required to be shot-blasted before they can be packaged and shipped to the customer’s place.

Technical Advantages


As many customers know, closed die forging process is not a recent innovation in the manufacturing field, it actually has been around for many years. On the other hand, it is critical to understand why closed die forging, other than casting, is the best suited process, and how to use this process as a competitive advantage over other processes for your part. Instead of using alternative methods, such as die casting to manufacture the parts required for a final assembly, closed die forging brings a variety of financial benefits, as well as efficiency from a part characteristics perspective:

*Structural Strength: Closed die forging can produce the strongest steel parts that is unmatched by other metalworking processes. It eliminates internal voids and gas pockets that will weaken metal parts. This ultimately reduces part inspection requirements and resources, simplifies heat treating and machining, and ensures optimum part performance especially when the part needs to be weight bearing and durable. In most cases, closed die forging is used to produce components that cannot fail and are located in critical areas of performance, such as vehicle engine blocks and transmissions.

*Low Scrap Rates: One of the most value-adding financial benefits of closed die forging is the fact that it leaves behind very little wasted material. During the forging process, the steel billets are simply heated and re-shaped, as opposed to raw material machining, which removes material, or casting, which involves much more processing of raw material. 

*Short Production Cycle: Closed die forging generally has shorter production cycle than its rival production methods. Forging only takes around 5 to 10 seconds per cycle compared to casting or machining where one cycle may potentially take minutes. This allows our closed die forging method to supply partners to maximize output and drive efficiency internally.

Early Buyer Involvement and Selection of Various Materials


We recently met with Mr. David, one of our long term cooperating customers, and discussed at great length the importance of the buyer and our engineering teams working closely and embracing the design for manufacturing mentality during the product design phase so that the mo(st feasible manufacturing process is identified at early stage, thus in case the design will be changed to remake the part in the future. We are the professional forging company that can provide redesign service for closed die forgings if needed.

Many buyers consider closed die forged components to be a simple component group to source and manufacture, but there have been several changes and recent innovations, including the growth of aluminum forged parts in the aerospace industry. Aluminum materials are becoming more common, especially in the aerospace and medical device industries, due to the increasing need to optimize performance and decrease part weight. As these complex parts become smaller and more lightweight, torque and stress on the parts tends to increase, which poses many design challenges. Even though processes like casting or metal injection molding tend to accommodate parts that contain complex features with tight tolerances more effectively, however, this innovation brings new opportunities for the forging industry that is highly capable of supporting these high-strength requirements.

Conclusion


Buyes should be well-versed within above guidelines before making a forging to ensure sourcing success. Closed die forgings are unique and every case must be analyzed and clearly understood prior to starting the procurement process. Keep in mind these guidelines and you will be well positioned to offer your company the best supply options while driving down your forging true cost, which will create a win-win value and relationship across closed die forging manufacturer and buyer. There are a lot of benefits to customize closed die forging from our company, contact us while you have such project.

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