Drop forging manufacturer


Home » News
With the most commonly used method, the billet is heated and placed into a special kind of tooling called a 'die'. The heated metal is put under extreme pressure and forced into the shape of the 'die'. Unlike the 'cut' that it once came from, the grain flow is directional and has been orientated in a way to increase strength/toughness (i.e increases steel ductility and impact resistance). Also, as no grain ends are exposed, a forged item is less susceptible to fatigue and stress. 

In short, the forging process adds an approx. 30% increase in strength/toughness over original billet it was made from. Compared to casting (forging vs casting), the initial tooling costs of forging are much more expensive, thus it is required to manufacture in high quantities to 'break-even' on the initial expense. But due to the advantages of forging, this is a very cost-efficient method for large volume production. 
What is grain structure? Grain flow is a directional orientation of metal grains and any inclusions that have been deformed by forging. Individual grains are elongated in the direction of the metal flow or plastic deformation. More importantly, nonmetallic inclusions, particles and other imperfections inherited from the casting process (forging vs casting) are elongated in the direction of grain flow. It should be noted that grain flow occurs to some degree in all metal-forming processes, not just forging. As a professional forging manufacturer, this article we would like to discuss how forging affects grain structure.

Grain flow is one of the major benefits by the use of forgings. Unfortunately, there are misconceptions on the topic, which include the underlying causes of grain flow, the benefits that can be accrued from grain flow and how to achieve an optimum grain flow. In the best case, grain flow results in more application of forgings, especially for some critical applications when safety and strength is considered.
Forging is a manufacturing process by which metal is pressed under great pressure into high strength desired parts. The process is normally (but not always) performed hot by preheating the metal to a desired temperature before it is worked. It’s important to note that the forging process is entirely different from the casting  process (forging vs casting), as metal used to make forged parts is never melted and poured as operated in the casting process. Forging refines the grain structure and improves the physical properties of the metal, so that the grain flow can be oriented in the direction of principal stresses encountered in actual use. Physical properties such as strength, ductility, and toughness are much better in a forging than in the base metal.

Forging can refine the grain structure of products. Forging is superior to casting or machining bar stock because the metal’s natural grain flow is made to conform to the shape of the product. Castings have an isotropic grain structure and, for a given part, may be as strong in compression loads, but standard and custom forgings are superior in tensile and shear loads due to the utilization of the grain flow. The structural reliability of forgings allows designers to trust the material to adhere to the safety factors of the design. It also can provide more uniform response to heat treatment and machining operations. 
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. 

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.
precision forging
It has been a popular trend that people source precision forgings from China. This creats lots of Chinese precision forging companies and also promotes the exporting in field of forging industry. 

We, Ningbo Fly Drop Forge Co.,Ltd is the leader in manufacturing precision forgings for industries like aerospace, Agriculture, Automotive, Rail, Military, Mining, Oil and Gas, Power Generation, Nuclear, Firearms, ect. Here "Precision Forging China" means precision forging components made in China. Today we would like  to talk about something all related to "Precision Forging China".

Recently, one of our clients from USA sent lots of samples to our drop forging company. These components was originally made by casting with steel. But the user found that the serving life of 
these casting products are short. To add the strength and longer the working life, they would like to use our closed die forging process instead.

From above case, you can see we can supply redesign service to our customers for closed die forgings. Our professional technical team will help you to redesign the parts according to the usage and our forging technology. Due to our specialty on forging, we can supply high quality forgings to customers. Thus they can sell or use well in their market, and we can win more orders for closed die forgings.
When choosing a metalworking process for your parts, you should be always confused at this problem. When designers or users begin to evaluate the benefits and performance of forgings with castings, they should realize that forging can offer competitive price-wise while delivering top-quality components. Additionally, with the develop of forging technology, modern forging facilities are able to produce forgings for applications with more complex shapes.

Pls note forging can not 100% replace of steel castings at present.  In some situations, casting is the best solution. If you insist on our forging technology, then you might have to change the design slightly so that your part can be shaped in our forging equipments. But if the design can not be changed, then you can not convert your casting part into forging. When working closely with your forging supplier, you should state your project in detail at the beginning of your project which outlines all your related issues. By the end of your discussions, your forging partner will be able to provide a solution that best solve the problems.
Price is the major factor that most American and Eourpean compaines source precision forgings in China. Especially for those precision forging distributors, they has a district control on the cost of finished precision forging parts. As a leading precision forging company in China, we would like to talk about how to source precision forgings in China. This article will guide our customers to source more prefessional precision forging manufacturers, and avoid any loss during the whole purchasing process.

In conclusion, cooperating with a good precision forging supplier is very important for your project. Any wrong decision will cause both time and money time. We, Ningbo Fly Drop Forging Co.,Ltd, are the specialized precision forging manufacturer for more than 30 years. Thanks to our high quality, competitive prices and good service, we always win good reputation from our customers. If you are now in the status of sourcing precision forgings from China, pls feel free to contact us.
Precision Forging is a process where metal is preheated and pressed into desires shapes with forging equipments in different tons. Precision Casting is the metal forming process by puring metal liquid into shell mold, cut the products from the tree assembling after cooling, and remove excess material for final product by polishing.

After forging, the inner grain structure is refined. So precision forging process creates products with better strength than those manufactured by any other metalworking process. Forging takes advantage of the metal’s natural grain flow, shaping the grain flow to conform to the contours of each part’s unique geometry. This grain flow contouring is called flash, and it will be removed by trimming dies. So normally, precision forged parts will require at least two pairs of moulds. Precision Forging can provide net shape products, which reduces further machining job and thus, machining cost can be saved. 

In order to achieve high surface hardness and surface roughness, improve fatigue strength, and meet working performance of drop forgings, Mechanical processing will be operated after carburizing treatment.  The mechanical processing after carburizing treatment is generally as follows:

1) Machining
The surface carbon content after carburizing is high, and after heat treatment, the surface of drop forged blanks will exsit a large amount of residual austenite, easy to form grinding cracks, such as burns and crack, in the process of grinding. Besides, grinding crack can also produce if there is thick carbide, carbide network or carbide film. So in the process of Mechanical Processing, we should refer to the technical requirements of carburizing forgings, choose the correct process parameters according to the specific characteristics. This will help improve the quality of the drop forgings, and can guide the actual machining.
Carburzing Treatment is a common heat treatment methods, it is a chemical process that carbon atoms entering the surface of drop forged products by heating drop forgings into carburzing medium and heat preservation, thus to increase the carbon content of surface layer, and form a certain carbon concentration gradient.

Materials of drop forgings that require carbuzing treatment are commonly selected as low carbon steel or low alloy steel (carbon content less than 0.25%). To maximum the working performance of carburizing treatment, drop forgings need to be quenched after carburizing treatment. Normally, the depth of carburizing treatment is 0.8-2mm. After carburizing,the surface hardness of drop forgings can reach HRC58-63, and the inner hardness can be HRC30~42. In addition, After carburizing, the surface of drop forgings will compress the internal stress, which will be beneficial to improve the fatigue strength of products. Therefore, carburizing is widely used in drop forging to impreve the strength, impact toughness and wear resistance, thus to longer the working life of forgings.
forged steel valve componentAccording to above information, we can see both forging and casting methods have its own advantages. In comparison to castings, the structure of forgings ensures wall thickness and dimensional tolerances are uniform. High impact closed die press forces and a segregation free billet guarantees superior strength, uniformity, integrity and density. Casting issues include inter granular corrosion, stress weakness, fatigue, cracks, porosity, sand pockets, weld repairs, scars, etc. 

Another benefit of forgings is the directional flow lines structure. Due to quality concerns brought about by low cost country valve manufacturing we now often see customers first specify a forging rather than a casting, then specify it must be a European forging and an approved brand, yet they then still ask for 100% MPI and UT on common A105 valves increasing the cost exponentially. Using good quality forging can reduce the need for NDT. Of course UT and MPI is a good idea to provide reassurance of the quality, especially for castings in larger sizes and higher classes.